Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Power Steering Gear

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See Figures 1 and 2



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Fig. Fig. 1: Troubleshooting the Power Steering Gear



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Fig. Fig. 2: Troubleshooting the Power Steering Gear

REMOVAL & INSTALLATION



See Figure 3



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Fig. Fig. 3: Exploded view of Volvo's power rack and pinion steering gear

140 and 1800 Series; 164 Models

See Figure 4

  1. Jack up the front end and support on jackstands.
  2.  
  3. Drain the oil from the steering pump as follows:
    1. Position a pan under the pump and remove the drain bolt from the pump.
    2.  
    3. Turn the steering wheel to full left lock. Remove the cover on the fluid reservoir.
    4.  
    5. Start the engine and allow it to run for a MAXIMUM of 10 seconds. This will run the pump and remove the fluid from the lines and reservoir. DO NOT run the engine without fluid in the system; the pump will become damaged.
    6.  
    7. Stop the engine and turn the wheel from lock to lock until all the oil has run out. Reinstall the drain plug.
    8.  

  4.  
  5. Remove the locknut for the Pitman arm. Disconnect the Pitman arm with a Pitman arm puller. When attaching the puller, turn the wheels fully to the right.
  6.  
  7. Disconnect the oil lines from the steering housing after cleaning the connections. Loosen the clamping bolt.
  8.  
  9. Remove the attaching bolts and pull the steering gear forwards.
  10.  



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Fig. Fig. 4: Details of the power steering system-140 and 160 series

To install:
  1. When reinstalling, place the steering gear in the middle position. A slight increase in resistance should be felt. The line-up marks on the steering spindle and gear housing should coincide.
  2.  
  3. Check to make sure that the steering wheel is pointing the front wheels straight ahead.
  4.  
  5. Install the steering gear shaft into the lower steering column section. Install and tighten the attaching bolts. Tighten the clamping bolt. Connect the oil lines. The longer line should run in a curve to the rear and be held with a clamp.
  6.  
  7. Point the front wheels straight and install the Pitman arm. Torque the nut to 125-141 ft. lbs. (170-191 Nm).
  8.  
  9. Fill the reservoir with Type A automatic transmission fluid and bleed the system as outlined under Power Steering System Bleeding.
  10.  

200 Series

See Figures 5, 6, 7, 8, 9, 10 and 11

  1. Disconnect the steering column shaft flange at the steering gearbox. Remove the clamp screw and pry the flange open.
  2.  
  3. Jack up the front end. Position jackstands at the front jack supports. Remove the front wheels.
  4.  
  5. Use a ball joint separator and disconnect the tie rods at the outer ends.
  6.  



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Fig. Fig. 5: Exploded view of the Saginaw power steering pump with integrated reservoir-as found on 260 series vehicles



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Fig. Fig. 6: Remove the nut that secures the tie rod end



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Fig. Fig. 7: Use a suitable tie rod end puller (such as the one shown)-the end is tapered and has a tight press fit. Hammering or prying will damage the threads, boot, etc., and still not work

  1. Remove the splash guard.
  2.  



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Fig. Fig. 8: The car should be jacked high enough to provide sufficient room to disconnect and remove the steering rack

  1. Disconnect the hydraulic hoses at the steering gear. Install protective plugs in the hose connections.
  2.  



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Fig. Fig. 9: Disconnect the hydraulic hoses at the steering gear, then install protective plugs in the hose connections-take care not to lose the sealing washer

On late model 260 cars, the hose clamp on the crossmember must be removed.



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Fig. Fig. 10: Unbolt the U-bolts or securing clamp that retains the power steering rack in place to the firewall



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Fig. Fig. 11: Lower the power steering rack through the left side of the vehicle-save the dowel pins

  1. Remove the bolts holding the steering gear. Remove the steering gear from its mounts and save the spacers.
  2.  
  3. Remove the steering gear from the car by pulling it down until it is free from the steering shaft flange. Then remove the unit through the left side of the vehicle. Save the dowel pins.
  4.  

To install:
  1. When reinstalling, position the steering gear and attach the pinion shaft to the steering shaft flange. Take care to align the recess for the lock bolt.
  2.  
  3. Install right side U-bolt and bracket, but do NOT tighten the nuts.
  4.  
  5. Install left side retaining bolts, and tighten. Tighten the U-bolts.
  6.  
  7. Connect the steering rods to the steering arms.
  8.  
  9. Install the lock bolt on the steering column flange.
  10.  
  11. Connect the return and pressure hoses to the steering gear. On late model 260s, secure the hose clamp to the crossmember.
  12.  
  13. Fill the reservoir with Type A automatic transmission fluid and bleed the system as outlined under Power Steering System Bleeding.
  14.  

700 Series
  1. Elevate the front end and safely support on jackstands. Place the stands at the front jacking points. Block the rear wheels.
  2.  
  3. Remove the splashguard and the small jacking panel on the front crossmember.
  4.  
  5. Disconnect the lower steering shaft from the steering gear.
  6.  
  7. At the lower universal joint, remove the snaprings and loosen the upper clamp bolt. Then remove the lower clamp bolt and slide the joint up on the shaft.
  8.  
  9. Use a ball joint separator and disconnect the tie rods at the outer ends.
  10.  
  11. Disconnect the fluid lines from the steering gear. Catch the spilled fluid in a pan and install plugs in the lines.
  12.  
  13. Remove the sway bar mounting brackets from the side members and move them out of the way. Remove the steering gear retaining bolts and lower the assembly out of the car.
  14.  

To install:
  1. Position the rack in position and install the retaining bolts. Tighten them to 32 ft. lbs. (43 Nm).
  2.  
  3. Install the sway bar mounting brackets.
  4.  
  5. Use new copper washers and connect the fluid lines to the assembly.
  6.  
  7. Connect the tie rods and tighten their nuts to 44 ft. lbs. (60 Nm).
  8.  
  9. Slide the lower universal joint down the shaft and into position. Tighten the lower clamp bolt first, then the upper. Both bolts are tightened to 15 ft. lbs. (20 Nm). Install the snaprings.
  10.  
  11. Reinstall the jacking plate and the splashguard.
  12.  
  13. Lower the car to the ground. Fill the reservoir with automatic transmission fluid. Start the engine and smoothly turn the steering wheel from lock to lock 3 or 4 times; recheck the fluid level in the reservoir.
  14.  

 
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