Chapter 1 Routine maintenance and servicing

Suspension and steering 10•15that one of the air bag module retaining boltsbecomes accessible from the rear of thesteering wheel. Undo the bolt, then turnthe steering wheel again until the second boltis accessible. Undo this bolt also.5 Withdraw the air bag module from thesteering wheel far enough to access thewiring multi-plug. Some force may be neededto free the module from the additional steeringwheel spoke retainers.6 Disconnect the multi-plug from the rear ofthe module, and remove the module from thevehicle.Warning: Position the air bagmodule in a safe place, with themechanism facing downwardsas a precaution againstaccidental operation.7 Turn the steering wheel so that theroadwheels are in the straight-ahead position,then remove the ignition key to lock thesteering.8 Release the wiring harness from the side ofthe steering column and disconnect the airbag module wiring multi-plug (yellow lead).9 Disconnect the wiring multi-plugs from thesteering column multi-function switchassembly.10 Disconnect the ignition switch wiringmulti-plug connector and remove the loomplate from its location on the left-hand side ofthe steering column.11 Undo the single screw and withdraw thePassive Anti-Theft System (PATS) transceiverfrom the ignition switch/steering lock barrel(see illustration 19.12).12 Unclip the bonnet release cable abutmentfrom its location in the steering column lockhousing, then detach the cable from thebonnet release lever by aligning the cablecore with the slot on the release lever andwithdrawing it through that slot. Detach thespring from the release lever arms, thendisengage the arms from the steering columnlock housing and remove the bonnet releaselever.13 Remove the C-clip at the base of thesteering column shaft, below the universaljoint.14 Remove the nuts securing the steeringcolumn mounting bracket.15 Pull the steering column assembly from itsbulkhead location and withdraw it from thevehicle, ensuring that the steering columnshaft and flexible coupling separate fully.Refitting16 Ensure that the roadwheels are in thestraight-ahead position and the steeringcolumn is locked. With the help of anassistant, insert the steering column assemblyinto the vehicle so that the steering columnshaft engages with the flexible coupling.17 Refit the steering column shaft C-clip.18 With the column assembly located looselyin position, refit and tighten the nuts securingit to its mounting bracket.19 Refit the steering column ancillarycomponents, reversing the removal proceduregiven in paragraphs 2 to 12.20 Reconnect the battery negative lead.22 Steering gear rubber gaiters- renewal31 Remove the track rod end balljoint asdescribed in Section 28.2 Remove the one-piece undertray wherefitted, by turning its bayonet-type fasteners,and on XR2i models, remove the frontsuspension crossmember as described inSection 7.3 Count the number of exposed threadsvisible, from the end of the track rod to thetrack rod end balljoint locknut, and record thisfigure. Now unscrew the locknut from thetrack rod.4 Release the clip(s), and slide the gaiter offthe rack-and-pinion housing and track rod.5 Scrape off all grease from the old gaiter,and apply to the track rod inner joint. Wipeclean the seating areas on the rack-andpinionhousing and track rod.6 Slide the new gaiter onto the housing andtrack rod, and secure with the retaining clips.Ensure that the narrow neck locates correctlyin the track rod groove.7 Screw the track rod end balljoint locknutback onto the track rod until the same numberof threads, as counted on removal, are visible.8 Refit the track rod end balljoint asdescribed in Section 28.9 Refit the front suspension crossmemberand one-piece undertray, as applicable.23 Steering gear(manual steering) -3removal and refittingRemoval1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe front roadwheels.3 Remove the one-piece undertray wherefitted, by turning its bayonet-type fasteners,and on XR2i models, remove the frontsuspension crossmember as described inSection 7.4 Remove the pinch-bolt securing the pinionsplined shaft to the lower steering shaftuniversal joints, located at the rear of theengine compartment.5 Separate the track rod end balljoints fromthe steering arms, as described in Section 28.6 Remove the lower brake servo supportbracket bolt.7 Remove the other bolt securing the steeringrack assembly to the bulkhead, then withdrawit from the right-hand side of the vehicle,taking care to disengage the pinion splinedshaft from the lower steering shaft universaljoint as the assembly is moved.Refitting8 Centralize the rack and steering wheel, thenengage the pinion splined shaft to the lowersteering shaft universal joint.9 Refit the steering rack assembly mountingbolts to the bulkhead and tighten to thespecified torque, ensuring that the servosupport bracket is correctly held.10 Refit the pinion splined shaft-to-lowersteering shaft universal joint pinch-bolt andnut and tighten to the specified torque,ensuring that the pinch-bolt locates to theannular groove as the pinion splined shaft.11 Refit the track rod end balljoints to thesteering arms, as detailed in Section 28. Aslong as the track rod end-to-track rod relativepositions have not been disturbed, it will notbe necessary to reset the front wheelalignment.12 Refit the front suspension crossmemberand one-piece undertray, as applicable.13 Refit the roadwheels, then lower thevehicle to the ground. Tighten the roadwheelnuts to the specified torque with the vehicleon its wheels.24 Steering gear(power steering) -4removal and refittingRemoval1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Chock the rear wheels then jack up thefront of the car and support it on axle stands(see “Jacking and Vehicle Support”). Removethe front roadwheels.3 Remove the one-piece undertray wherefitted, by turning its bayonet-type fasteners,and on XR2i models, remove the frontsuspension crossmember as described inSection 7.4 Remove the pinch-bolt securing the pinionsplined shaft to the lower steering shaftflexible coupling, located at the rear of theengine compartment.5 Undo the retaining screws, and detach theclips securing the power steering hydraulicpressure pipes to the steering gear.6 Position a suitable container under thehydraulic pipe connections to the steeringgear. Unscrew the pipe unions, then detachthe pipes from the valve body. Withdraw thepipes from the steering gear, and drain thehydraulic fluid into the container.7 Plug the exposed ends of the hydraulic lineconnections, to prevent the ingress of dirt andfurther fluid loss. Note that new O-ring sealswill be needed for the pressure and returnhose connections when reconnecting.8 Slacken the upper bolts securing thesteering gear support brackets. On left-hand101595Ford Fiesta Remake