Section of the steering gear housing
1 – Bipod shaft adjusting screw plate; 2 – adjusting screw of the bipod shaft; 3 – adjusting screw nut; 4 – oil filler plug; 5 – steering gear housing cover; 6 - worm; 7 – steering gear housing; 8 – bipod; 9 – nut for fastening the bipod to the shaft; 10 – spring washer for bipod mounting nut; 11 – knuckle shaft cuff; 12 – bronze sleeve of the bipod shaft; 13 – bipod shaft; 14 – roller of the bipod shaft; 15 – worm shaft; 16 – upper ball bearing; 17 – lower ball bearing; 18 – adjusting shims; 19 – lower worm bearing cover; 20 – roller axis; 21 – needle bearing; 22 – worm shaft seal.
We drain the oil from the gearbox housing, unscrew the adjusting nut and remove the lock washer.
Using a 10 mm spanner, unscrew the four bolts securing the top cover of the gearbox.
We remove the head of the adjusting screw from the groove on the bipod shaft and remove the cover.
When replacing the bipod shaft, the axial clearance between the screw head and the shaft groove is eliminated by selecting the thickness of the adjusting plate. The clearance value is allowed to be no more than 0.05 mm. The plates have a thickness from 1.95 to 2.20 mm with a step of 0.025 mm.
We remove the knuckle shaft with the roller from the crankcase.
Using a 10 mm spanner, unscrew the four bolts securing the worm shaft cover and...
...we remove it together with the ball bearing adjustment linings.
The gaskets are available in thicknesses of 0.1 and 0.15 mm.
Using light blows from a soft metal hammer, knock the worm shaft out of the gearbox housing together with the bearing.
The end surfaces of the worm are provided with raceways for bearing balls.
Using a screwdriver, we remove the worm shaft cuff.
We remove the knuckle shaft cuff in the same way.
We knock out the outer ring of the second bearing with a punch.
Wash all parts in kerosene or diesel fuel. Carefully check the working surfaces of the roller and worm for signs of wear, scoring or damage. The gap between the pitman shaft and bronze bushings should not exceed 0.1 mm. Ball bearings should rotate freely, without jamming, there should be no damage or signs of wear on the surfaces of rings, separators and balls. Cracks of any length are not allowed on the crankcase itself. Replace worn and damaged parts with serviceable ones. Replace cuffs with new ones in any case. Before assembly, lubricate all internal parts with transmission oil.
Using light hammer blows on a piece of pipe of a suitable diameter, press the inner bearing ring into the crankcase.
The bearing ring can be pressed in using the front suspension rubber-to-metal joint replacement tool (see Applications).
We install a separator with balls in the bearing ring and insert the worm shaft. We put the separator of the outer bearing on it and press the outer ring with light hammer blows. We put the cover with gaskets and...
...we press in the worm shaft and pitman arm seals, lubricating the working edges with Litol-24 grease.
We install the worm in the crankcase. Using a set of adjusting linings, we set the moment of its rotation from 2 to 5 kgf cm. We install the pitman shaft and adjust the clearance in the engagement according to the moment of shaft rotation. It should be 7–9 kgf cm when turning the worm shaft by 30° to the left and right and smoothly decrease to 5 kgf cm with further rotation to the stop.
Fill the crankcase with transmission oil to the level of the lower edge of the filler hole (0.215 l).
(The article is taken from an online resource: VazBook)
Dimensions of the main mating parts and limits of permissible wear
Mating parts | Dimensions of mating parts, mm | Permissible clearance in the mating, mm | |||||||
Hole | Shaft | ||||||||
| Steering Arm Shaft Bushing – Steering Arm Shaft | 28,698 +0,022 | 28,690 -0,021 | 0,1 | ||||||
| Steering gear housing - upper worm bearing |
| 47 -0,011 | Free play is not allowed | ||||||
| Steering gear housing - lower worm bearing | 50 0,025 | 50 -0,011 | 0,06 | ||||||
| Pendulum Arm Bracket - Pendulum Arm Axle Bushing |
|
| 0,175 | ||||||
| Pendulum Arm Axis Bushing – Pendulum Arm Axis |
| 20 -0,050 | 0,3–0,5 | ||||||