Volvo 240/740/760/780/940/960 1990-1998

Manual Rack and Pinion

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This procedure applies only to 240 series vehicles with manual rack and pinion assemblies. All other models of the 240 series, as well as all other vehicles covered by this guide, have a power rack and pinion; for those vehicles, refer to the procedure later in this section.

REMOVAL & INSTALLATION



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the lockbolt and nut from the column flange.
  4.  
  5. Bend apart the flange slightly with a screwdriver.
  6.  
  7. Raise and support the vehicle safely.
  8.  
  9. Remove the front wheels.
  10.  
  11. Disconnect the tie rod ends, using a ball joint puller.
  12.  
  13. Remove the splash guard.
  14.  
  15. Disconnect the steering gear from the front axle member (beam).
  16.  
  17. Disconnect the steering gear at the steering shaft flange.
  18.  
  19. Remove the steering gear. Save the dowel pins.
  20.  

To install:
  1. Install rubber spacers and plates for the steering gear attachment points.
  2.  
  3. Position the steering gear and guide the pinion shaft into the steering shaft The recess on the pinion shaft should be aligned towards the lockbolt opening in the shaft
  4.  
  5. Attach the steering gear to the front axle member.
  6.  
  7. Check that the U-bolts are aligned in the plate slots. Install flat washers and nuts. Tighten the nuts to 10-18 ft. lbs. (14-25 Nm).
  8.  
  9. Install the splash guard.
  10.  
  11. Connect the steering rods to the steering arms. Tighten the nuts to 44 ft. lbs. (60 Nm).
  12.  
  13. Install the front wheels.
  14.  
  15. Lower the vehicle.
  16.  
  17. Install the lockbolt for the steering shaft flange. Tighten the bolt to 18 ft. lbs. (25 Nm).
  18.  
  19. Have the alignment checked and reset if needed.
  20.  
  21. Connect the negative battery cable.
  22.  

 
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