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HOMESERVICE MANUALSVOLVO1994940 BASE, 4D SEDAN, AW71REPAIR AND DIAGNOSIS (SINGLE PAGE)STEERINGMANUAL STEERINGSTEERING SYSTEM - POWER RACK & PINIONOVERHAULSTEERING GEARREASSEMBLY
1994 Volvo 940 Base, 4D Sedan, AW71

Steering Gear: Reassembly

1994 Volvo 940 Base, 4D Sedan, AW71SECTION Reassembly
  1. Coat all parts with ATF before assembly. Install NEW "O" ring and Teflon ring on rack piston. If difficult to install, heat Teflon ring 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 using 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 rack to seat seal and spacers.
  5. To ensure seal is correctly positioned, look through pressure tube opening to ensure at least half of piston seal retainer has passed center of opening. Position rack so end protrudes about .750" (19 mm) from 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. Install plastic spacer with beveled side facing toward seal. 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. Ensure rack locking wire opening is 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 Cam Gear Pinion (940)
    G52922Courtesy of VOLVO CARS OF NORTH AMERICA
  10. Wrap pinion splines using tape. Install lower pinion lock nut. 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). Pack lower pinion cover with Lubricant (11 61 001-1). Install preload piston assembly in housing.


  1. Lubricate all parts with ATF before reassembly. Install "O" ring and Teflon ring on rack piston. If difficult to install, heat Teflon ring in water to 104-122°F (40-50°C).
  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 farther 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 .750" (19 mm) from pinion housing end of rack housing. DO NOT push rack farther into housing or seal may be damaged.
  5. Install bushing, spacer washer and seal in end sleeve. Seal lips face outward 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 upward. 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). Fill pinion housing lower cover with grease and install.
  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 2 . 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.
  13. Move rack from lock to lock and note maximum indicator reading. Subtract .004" (.10 mm) from maximum indicator reading to achieve total thickness of shim to be installed.
  14. Remove dial indicator and counterhold. Install "O" ring on preload piston. Install preload piston with spring, 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 1: Exploded View Of ZF Steering Gear (940)
G59101Courtesy of VOLVO CARS OF NORTH AMERICA
RENDER: 1.0x

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