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HOMESERVICE MANUALSVOLVO1987760 TURBO, 4D WAGON, AW71LREPAIR AND DIAGNOSIS (SINGLE PAGE)STEERINGMANUAL STEERINGSTEERING SYSTEM - POWEROVERHAULSTEERING GEARREASSEMBLY
1987 Volvo 760 Turbo, 4D Wagon, AW71L

Steering Gear: Reassembly

1987 Volvo 760 Turbo, 4D Wagon, AW71LSECTION Reassembly
  1. If removed, lubricate needle bearing with lubricant (Part No. 1161001-1 ). Using a drift, install needle bearing into pinion housing so it is 2.29-2.31" (58.2-58.6 mm) from seal bottom. See Fig 1 .
  2. Using Driver and Drift (1801 and 5184 ), install seal and "O" ring into pinion housing. Install bronze bushing in spacer tube with chamfered side toward inside of tube.
  3. Install seal in spacer tube with lips facing away from inside of tube. Coat seal lips with lubricant.Install spacer washer, lock ring, Teflon ring and "O" ring onto spacer tube.
    Fig 1: Installing Needle Bearing (240 Series ZF Gear)
    G59092Courtesy of VOLVO CARS OF NORTH AMERICA.
  4. Before install spacer tube on rack, coat rack snap ring groove with wheel bearing grease. Slide spacer tube on steering rack from smooth end. Do not damage seal on snap ring grooves.
  5. Install piston ring on piston. Install inner lock ring, spacer washer, "O" ring, piston with ring, spacer washer and lock ring onto rack in that order.
  6. Install tube locking collars with recesses for wrench facing center of tube. Install locking rings on tube. Lubricate and install "O" rings on tube.
  7. Using Drift and Driver (5184 and 1801 ), install seals in right side end housing. Using drift and driver, install metal bushing, Teflon bushing, and star washer in right side end housing.
  8. Apply ATF to tube "O" rings. Using Spanner Wrench (5178 ), attach tube to right side end housing. Tighten to 88 ft. lbs. (120 N.m).
  9. Coat rack teeth with lubricant (Part No. 1161001-1 ). Install rack with spacer assembly into pinion housing. Attach right side end housing/tube assembly to pinion housing.
  10. Line up marks made during disassembly. Using Spanner Wrench (5178 ), tighten retaining collar to 88 ft. lbs. (120 N.m).
  11. Using a sharp punch, stake right side end housing at one of the locking collar wrench recesses. Center rack so it protrudes 1 7/8" (48 mm) from pinion housing.
  12. Install seal rings on guide bushing. Install guide bushing on pinion shaft. Align guide bushing with dowel pin on shaft. Using Drift (5226 ), drive seal into valve housing. Grease rollers (20) and install into roller cage.
  13. Using Driver and Drift (1801 and 5227 ), install roller bearing assembly into pinion housing. Install pinion assembly into valve housing. Large end of pinion shaft should protrude .20" (5.0 mm) from valve housing face. See Fig 2 .
    Fig 2: Installing Pinion Assembly in Valve Housing (240 Series ZF Gear)
    G59093Courtesy of VOLVO CARS OF NORTH AMERICA.
  14. Install valve housing assembly to pinion housing. Flat on pinion assembly should face toward exposed rack end. Do not pinch "O" ring between valve and pinion housings. Install and tighten pinion-to-valve housing screws to 18 ft. lbs. (25 N.m). Install dust cover on pinion shaft.
  15. Install preload piston with depressor but without "O" ring. Set up Preload Measuring Fixture (5865 ) using cover bolt hole and an 8 x 45 mm bolt. Assemble fixture with preload spring between bolt head and bolt. See Fig 3 . Screw in tool spindle until it tensions piston but not lock rack.
    Fig 3: Adjusting Rack Preload
    G59094Courtesy of VOLVO CARS OF NORTH AMERICA.
  16. Use depth micrometer to measure pinion housing-to-preload piston distance. Check measurement at 3 different points on steering rack to determine piston's highest point. Subtract .004-.006" (.10-.15 mm) from smallest reading obtained. This value equals thickness of spacer washer to be installed.
  17. Washers are available in thickness of 2.1-2.90 mm in increments of .05 mm. Remove measuring fixture. Lubricate "O" ring and install on preload piston. Install piston spring and spacer washer measured in step 16). Fill space around spring with lubricant (Part No. 111600-01 ).
  18. Apply sealant on cover sealing surface. Install and tighten cover bolts to 16 ft. lbs. (22 N.m). Install and tighten pressure lines. Ensure "O" rings seat correctly.
  19. Install tie rods. Bend back tie rod locking tabs. Install boots. Fill each boot with approximately 3/4 ounce of lubricant. Install boot clamps. Install equalizer tube and plastic clamps.


  1. Coat all parts with ATF before assembly. Install new "O" ring then Teflon ring on rack piston. Heat Teflon ring is difficult to install, heat it in water to about 100°F (40°C).
  2. Using Seal Drive (5277 ) and Handle (1801 ), install lower pinion seal and guide sleeve in housing. Seal ring lip must face up. If seal is not centered properly, pinion will not turn easily.
  3. Install lower bearing and lock ring. Wrap rack teeth with tape. Install seal with lip facing piston seal. Install tapered spacer with tapered side facing seal. Install flat spacer.
  4. Press 2 spacers together. Remove tape from rack. Lube rack teeth. Install rack in housing. As rack seats, lightly push on it to seat seal and spacers.
  5. To check is seal is correctly positioned, look through pressure tube opening. At least half of piston seal retainer has passed center of opening. Position rack so the end protrudes about 3/4" end of housing next to pinion housing.
  6. Clean end of rack with wet fine-grit sandpaper. Clean rack and wrap one turn of tape around rack edge. Lubricate rack and tape.
  7. On late type gears, install plastic spacer with beveled side facing toward seal. On early and late type gears, install lock sleeve and bushing onto rack. Use small screwdriver to lift edge of seal on end of rack.
  8. Position end of lock sleeve so cut out sections face end of rack. Rack opening for locking wire must be in line with elongated hole in tube. Install locking wire. Turn bushing until wire is positioned correctly.
  9. Center rack in housing and lubricate teeth with grease. Place pinion in housing with flat side in any one of 3 correct positions. See Fig 1 . End of rack should protrude 2.2" (55 mm).
    Fig 1: Positioning 700 Series Cam Gear Pinion Assembly (Early & Late Versions)
    G52922Courtesy of VOLVO CARS OF NORTH AMERICA.
  10. On early version steering gears, wrap pinion splines with tape. Install upper bearing on pinion with bevelled side down. Lubricate and install upper seal with lip facing down. Install snap ring and dust cover.
  11. Install lower pinion lock nut. Tighten lock nut to 27 ft. lbs. (37 N.m).
  12. On late version steering gears, follow procedures in steps 10) and 11) EXCEPT pinion lock nut is installed BEFORE installing bearing and upper seal.
  13. Pack lower pinion cover with lubricant (Part No. 11 61 001-1 ). Install preload piston assembly in housing.


  1. Lubricate all parts with ATF prior to reassembly. Install "O" ring and Teflon ring on rack piston. Heat Teflon ring in water to 104-122°F (40-50°C) if it hard to install.
  2. Install seal over rack teeth with lip facing piston. Lubricate rack piston teeth. Place spacer ring next to seal.
  3. Install rack with seal and spacer ring into housing. When rack seats, gently push it in further to seat seal and spacer ring. Rack is positioned correctly when rack seal is visible in center of outlet tube hole.
  4. Position rack so end protrudes about 3/4" from pinion housing end of rack housing. DO NOT push rack further into housing or seal may be damaged.
  5. Install bushing, spacer washer and seal in end sleeve. Seal lips face out from end of sleeve. Drive end sleeve in housing and secure with snap ring.
  6. Install "O" rings and Teflon rings (if removed) on spool valve. If necessary, heat Teflon rings in water to 104-122°F (40-50°C) to ease installation.
  7. Install bearing and "O" ring in upper bearing housing. Install seal with lip facing bearing. Install lower pinion seal in pinion housing with lip facing up. Install lower pinion bearing and lock ring.
  8. Install pinion and spool valve assembly in pinion housing. Install upper bearing housing, spacer washer, snap ring and dust shield. Pack bottom of dust shield with grease.
  9. On bottom of pinion and spool valve assembly, install spacer washer and tighten lock nut to 11 ft. lbs. (15 N.m). Install pinion housing lower cover after filling it with grease.
  10. Center steering rack in housing. Install preload spring WITHOUT "O" ring. Install spring in piston.
  11. Install Counterhold (2985 ) on steering rack. See Fig 1 . Install dial indicator with stem on rack housing. Zero dial indicator.
  12. Turn dial indicator so tip rests on face of preload piston. Note reading.
    Fig 1: Checking Rack Preload (700 Series ZF Steering Gear)
    G59100
  13. Move rack from lock to lock and note maximum indicator reading. Subtract .004" (.10 mm) from maximum indicator reading. This is total shim thickness that must be installed.
  14. Remove dial indicator and counterhold. Install "O" ring on preload piston. Install preload piston with spring and shim and cover. Tighten bolts to 79 INCH lbs. (9 N.m).
  15. Install boot "O" ring and steering rods. Stake steering rods to rack to secure in position. Install boots and clamps.
Fig 2: Exploded View of 700 Series ZF Steering Gear
G59101Courtesy of VOLVO CARS OF NORTH AMERICA.
RENDER: 1.0x

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