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DAF CF65, CF75, CF85 Series . Manual - part 964

200423

4-1

Removal and installation

STEERING BOX

ΧΦ65/75/85 series

4. REMOVAL AND INSTALLATION

4.1 REMOVAL AND INSTALLATION, ENTIRE STEERING BOX

If the vehicle has been involved in a

collision in which the steering box or

other components of the steering

gear have (possibly) been damaged,

the steering box should always be

sent to DAF for inspection or be

replaced. This instruction even

applies if no external damage is

visible. In the collision, the steering

box may have sustained internal

damage, causing it to be unreliable.

Removing the entire steering box
1.

Clean the steering box and the surrounding

area.

Place the steering gear in the central

position. This can be checked using the

markings on the steering box.

With an EMAS-controlled trailing axle,

remove the connector from the angle sensor.

Remove the steering oil pipes from the

steering box. Collect the steering oil flowing

out and plug the openings of the pipes and at

the steering box, to prevent dirt entering.

Note:

If the pipe connections might accidentally be

switched, they should be marked.

Remove the steering rod from the pitman

arm.

Note:

When a steering rod has been removed, the

input shaft must not be rotated more than

1.5 turns (counting from the central position)

because otherwise the setting of the wheel

deflection limiting valves will be changed.

If present, detach the wiring harness and/or

other pipes from the steering bracket.

Remove the steering shaft from the steering

box input shaft.

Note: The steering box weighs

approx. 35 kg. The steering box

should be supported securely and

responsibly, or safely suspended in

a hoist.

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S7 00 024

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STEERING BOX

4-2

200423

Removal and installation

ΧΦ65/75/85 series

Remove the attachment bolts from the

steering box to the steering bracket and

remove the steering box from the vehicle.

Keep the removed bolts to check the length

of the new bolts.

With an EMAS-controlled trailing axle,

remove the angle sensor from the steering

box, if necessary.

Installing the entire steering box
1.

Carefully clean and inspect the threaded

holes of the steering box.

Remove all paint, dirt, grease, etc. from the

contact surfaces of both the steering box and

the steering bracket (a thin, factory-applied

layer of paint is allowed). The contact

surfaces should be absolutely free from dirt

and grease.

In the case of the new or revised steering

box, fit the pipe connections. For the

connection points, see 'Technical data'.

With an EMAS-controlled trailing axle, fit the

angle sensor to the steering box, if

necessary.

Replace the attachment bolts. Because the

yield stress is exceeded while tightening the

bolts, they may not be re-used.

Check that the new bolts are exactly the

same length as the removed bolts.

Grease the new bolt sparingly. On no

account should you over apply the lubricant.

This could result in the connection coming

loose.

Carefully check the length of the new

bolts. If the bolts used to fit the

steering box are too long, they can

lock in the steering box thus

resulting in insufficient pre-load.

Fit the steering box equipped with a pitman

arm to the steering bracket. Make sure that

the locating bolt is fitted into the middle

threaded hole under the steering box.

Tighten the attachment bolts evenly.

Tighten the bolts to the specified tightening

torque. See 'Technical data'.

Fit the pipes to the steering box.

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200423

4-3

Removal and installation

STEERING BOX

ΧΦ65/75/85 series

Fit the new, original locating bolt and nut in

the universal joint.

Tighten the bolt to the specified torque, see

'Technical data'.

10. Fit the steering shaft to the steering box input

shaft. The groove (A) in the coupling must be

aligned with the mark (B) on the input shaft of

the steering box.

Check that the steering shaft is

correctly fitted to the input shaft, so

that the bolt can be fitted in the

recess (C).

11. Install the steering rod.

12. Fit the cable harness and/or other pipes back

in their original position.

13. With an EMAS-controlled trailing axle, fit the

connector to the angle sensor.

14. Fill and bleed the steering gear, see 'Filling

and bleeding'.

15. If the steering box input shaft may have been

rotated more than 1.5 turns (as seen from the

central position) while the steering rod was

removed, the final limiting pressures should

be checked. See 'Inspection and

adjustment'.

16. With an EMAS-controlled trailing axle,

calibrate the EMAS system.

17. Make a test drive. During the test drive, the

proper functioning of the steering gear

should be checked. After the test drive, the

system should be checked for leaks.

K1 01 353

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STEERING BOX

4-4

200423

Removal and installation

ΧΦ65/75/85 series

4.2 REMOVAL AND INSTALLATION, STEERING BRACKET

Be careful when tilting the cab or

when working under the tilted cab if

the steering bracket is to be

inspected or replaced because of a

collision. Vital parts of the cab

suspension may have been

damaged. Take the necessary

precautions.

Removing the steering bracket
1.

Remove the steering box.

Support the steering bracket. Remove the

attachment bolts and take the steering

bracket off the chassis.

After a collision, the steering bracket

should be inspected very carefully

for deformation and cracks. This is

important for vehicle safety. If

possible, the steering bracket

should be magnaflux tested. If in

doubt, always replace the steering

bracket.

Re-using attachment bolts
As bolts are tightened to breaking point, every

bolt should be inspected before it is re-used.

Clean the bolt thread thoroughly.

Check the thread for damage. To do so,

manually screw a new nut onto the thread to

be checked. If the new nut cannot be fully

hand-screwed onto the entire thread of the

bolt to be checked, it is not allowed to re-use

the bolt.

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