Sheppard M-Series Power Steering Service Manual

M-Series Power Steering Service Manual “ ” “We provide personal customer support through training and education programs, a telephone hotline and technical ﬁeld assistance, as well as one of the best warranty programs in the business.” Peter H. Sheppard President Part # 1000400 REV. A

1 SECTION DESCRIPTION PAGE I SAFETY NOTICE..........................................................................................2 Introduction ....................................................................................................3 Oil Flow ..........................................................................................................5 Gear Identiﬁcation ..........................................................................................6 Exploded View of Steering Gear ....................................................................7 Service Parts Kits/Lubrication........................................................................8 II DIAGNOSIS & TROUBLESHOOTING......................................................9 Glossary..........................................................................................................14 Troubleshooting Guide ..............................................................................15-18 III COMMON PROCEDURES ........................................................................19 Preventive Maintenance ................................................................................ 20 Input Shaft Seal Replacement ...................................................................... 22 Sector Shaft Seal Replacement .................................................................... 30 Bleeding Single Gear ....................................................................................28 Bleeding Dual Steering Gears ......................................................................29 Axle Stop Adjustment....................................................................................32 Alternate Bleed Procedure ............................................................................33 Set Relief Plungers Manual Plungers Adjustment ...................................... 42 Set Automatic Relief Plungers ......................................................................35 Adjust Automatic Relief Plungers ................................................................ 36 Repair Automatic Relief Plungers ................................................................37 Pitman Arm Removal ....................................................................................41 Pitman Arm Installation ................................................................................43 Input Shaft Seal Replacement (M-110P2) ....................................................45 IV DISASSEMBLY ............................................................................................49 VI REASSEMBLY ............................................................................................55 VII DUAL STEERING SYSTEMS ....................................................................61 VIII FINAL ADJUSTMENTS ..............................................................................65 IX MISCELLANEOUS......................................................................................66 Troubleshooting Checklist ............................................................................66 Order Sheet - Heavy Duty Power Steering Test Kit ....................................67 Index

2 STOP! Before you begin, please read this manual carefully. The repair procedures outlined in this manual are for repairing the Sheppard Integral Power Steering Gear. To ensure safe and reliable operation, these service and repair procedures must be followed carefully. THIS MANUAL CONTAINS A NUMBER OF SAFETY SIGNAL WORDS LIKE: DANGER, WARNING, CAU- TION, IMPORTANT, or NOTE. The information following a safety signal word is very important. When you see the word it means the information will help you avoid an extreme hazard that could kill or cause a very serious injury every time. When you see the word it means there is a hazard that is not as serious as DANGER but the hazard could cause injury or death if you do not follow the proper rules or procedures. When you see the it means the information that follows will help avoid damage to the steering gear. The signal words IMPORTANT or NOTE are used to draw attention to ways of doing your job better or right. WARNING WARNING DANGER CAUTION SAFETY NOTICE

3 INTRODUCTION This service manual covers repair procedures for the Sheppard steering gear assembly only. The Vehicle Manufacturer’s Service Manual should be used for removal and reinstallation instructions, and hydraulic supply pump speciﬁcations. Any reference made to a brand name, special tools or item part number are made as a guide. All information, illustrations and speciﬁcations in this manual are the latest available at the time of printing. We reserve the right to make changes without notice. If you are not certain you have the current revision of this manual or if you have questions about procedures, please call our Field Service Department at 717-633-4111 before you begin repairs. I N T R O D U C T I O N

4 OPERATING PRINCIPLES The Sheppard M-Series Integral Power Steering Gear provides full-time hydraulic steering. Only enough manual effort to overcome the torsion bar and turn the rotary valve is required. The actuating shaft (1) is connected to the steering column and is centered within the rotary valve by a torsion bar. The rotary valve shaft is threaded into the piston with ball threads (2) and travels within the piston on steel balls. Rotating the input shaft causes high pressure fluid to build up on one end of the piston. This higher pressure causes the piston to move in the bore of the gear housing. The sector shaft (3) is engaged to a rack gear (4) machined into one side of the piston. Piston rack movement causes sector shaft and pitman arm rotation. When steering shaft rotation stops, the actuating valve returns to its neutral position. Relief valve plungers or adjustable stops are used in the bearing cap and cylinder head. When the plungers are adjusted properly, they will unload the hydraulic system if the wheels are in a full turn to either direction. When the engine is running there is constant low pressure oil flow through the steering gear. This constant oil flow provides an instant response and absorbs road shock to help eliminate steering wheel kick. Pressure is equal throughout the steering gear; however, care should be used when towing or moving a vehicle where the engine or hydraulic supply pump is not running. If sudden loss of pressure occurs during normal driving, the parts are designed to provide mechanical back-up steering so that the vehicle may be safely steered to the side of the road. An optional integral pressure relief valve is available on the M-Series Steering Gears. This valve limits maximum steering system relief pressure at the steering gear. This reduces system temperature by avoiding high pressure by-pass and recirculation within the pump. The Sheppard Integral Power Steering Gears have been designed to provide long service life and simple service repair. The rack and sector shaft does not require center point adjustment. The clearance between the cylinder bore and the piston is closely controlled, and a piston ring (5) was added to better use the hydraulic oil supplied. With reasonable care and limited maintenance the Sheppard M-Series Steering Gear will provide many miles of reliable performance. NOTE: BEARING CAP (1) ACTUATING SHAFT (5) PISTON RING (3) SECTOR SHAFT (4) PISTON RACK RELIEF PLUNGER CYLINDER HEAD TORSION BAR (2) ROTARY VALVE SHAFT BALL THREAD

5 OIL FLOW THROUGH THE M-SERIES GEAR Figure 1 Here we see the steering gear in the neutral or non steering position. Equal low pressure is being applied to both ends of the steering gear piston. The oil is circulat- ing at back pressure only and provides a hydraulic cush- ion for the steering gear. All oil is being circulated through the steering gear and back to the reservoir to help cool the system. Figure 2 When the steering wheel is turned, the actuating valve is opened in one direction, all pressurized oil is applied to one end of the steering gear piston. This pressure build up causes the piston to move in the steering gear. Figure shows all oil being distributed to the input end of the gear. Figure 3 Figure shows all oil being distributed to the cylinder head end of the gear. Figure 1 Figure 2 Figure 3 When no input is applied through the steering wheel the gear returns to the neutral or non steering position. I N T R O D U C T I O N

6 A number is cast into the steering gear housing and identifies the basic family the steering gear belongs to. Stamped letters and numbers on an exposed machined surface of the housing (opposite the mounting side) identifies the gear specification; see gear P/N chart below. In the above example the complete identification is Model M- 100PAD1A1. Cast number M-100 would refer to the M-Series steering gear family. GEAR P/N CHART M-100 P H B1 SERIES GEAR (REVISION LEVEL) MODEL NUMBER ALPHABETICALLY POWER GEAR SIZE A serial number is also assigned to each steering gear and is interpreted below: SERIAL NUMBER SYSTEM THIS SERIAL NO. IS 00C15914 00 2000 (Used Last Two No’s) C MO. Built A-Jan B-Feb. C-Mar. Etc. 15914 Sheppard Ref. Only REPRESENTS: (00) YEAR BUILT – 2000 (C MONTH – MARCH (15914) REF. ONLY ➔ ➔ ➔ STEERING GEAR IDENTIFICATION

7 SERVICE PARTS LIST 1 HOUSING (NOT SOLD SEPARATELY) 2 CYLINDER HEAD (NOT SOLD SEPARATELY) 3 BEARING CAP/SHAFT ASSEMBLY 4 SECTOR SHAFT COVER (NOT SOLD SEPARATELY) 5 SECTOR SHAFT 6 PISTON ASSEMBLY (NOT SOLD SEPARATELY) 7 PRESSURE RELIEF CARTRIDGE 8 PITMAN ARM RETAINER 9 PITMAN ARM (SOLD BY APPLICATION) 10 INPUT SHAFT SEAL KIT 11 SECTOR SHAFT SEAL KIT 12 CYLINDER HEAD PLUNGER KIT 13 BEARING CAP PLUNGER KIT 14 BLEEDER PLUG KIT I N T R O D U C T I O N

8 M100 COMPLETE SEAL KITS: Sheppard Part No. 5543211 Complete seal kit for all M100 steering gears with push-on dust boot on sector shaft Sheppard Part No. 5542331 Complete seal kit for all M100 steering gears with a pressed-in excluder seal on the sector shaft Sheppard Part No. 5543481 Complete seal kit for all M100 steering gears with a snap-ring cover and a push-on dust boot at the sector shaft Sheppard Part No. 5543491 Complete seal kit for all M100 steering gears with a snap ring cover and a pressed-in excluder seal on the sector shaft M90 COMPLETE SEAL KIT Sheppard Part No. 5543551 Complete seal kit for all M90 steering gears M80 COMPLETE SEAL KITS: Sheppard Part No. 5543461 Complete seal kit for all M80 steering gears M110 COMPLETE SEAL KITS: Sheppard Part No. 5541411 Complete seal kit for all M110P2 steering gears Sheppard Part No. 5542621 Complete seal kit for all M110P1 steering gears M-SERIES INPUT SHAFT SEAL KITS: Sheppard Part No. 5542261 Input shaft seals for all M-Series gears built from June 1991 to present Sheppard Part No. 5541351B Input shaft seals for all M-Series gears built prior to June 1991 M100 SECTOR SHAFT SEAL KITS: Sheppard Part No. 5542271 Sector shaft seals for all M100 steering gears with a pressed-in excluder seal at the sector shaft with bolt on case Sheppard Part No. 5543601 Sector shaft seals for all M100 steering gears with a push-on dust boot at the sector shaft and a snap ring cover Sheppard Part No. 5543591 Sector shaft seals for all M100 steering gears with a pressed-in excluder seal at the sector shaft and a snap ring cover Lubrication - Steering Gears FLUID RECOMMENDATIONS The lubricant used in the power steering system lubricates moving parts and removes heat. Too much heat reduces efficiency and increases wear. It is important to use the lubricant specified by the Vehicle Manufacturer and approved by the R. H. Sheppard Co., Inc. R. H. Sheppard Co., Inc. approves the use of the following fluids in the M-Series steering gear: R. H. Sheppard Company Approved Fluids for Power Steering Automatic Transmission Fluid Dexron III Automatic Transmission Fluid Type “E” or “F” Castrol Supreme XHD 15W40 Castrol MP Dexron III/Mercon Castrol TransSynd Chevron Delo 400 Multigrade 15W40 Chevron Dexron III/Mercon Chevron RPM Heavy Duty Motor Oils 15W40 Chevron 10W40 Supreme Cummins Premium Blue 2000 15W40 ELF Lubricants XT2388 / Dexron III Exxon Auto H32 Hydraulic Fluid Exxon Firexx HF-DU68 Fleetrite PSF (CH990625) Ford Spec. M2C138CJ Mack EOM Plus Mobil 1 0W30 Tri-Synthetic Mobil 1 15W50 Motor Oil Mobil ATF 210 Mobil Quintolubric 822-220 Mobil Super 10W40 Motor Oil Mobil Super 15W40 Motor Oil Shell Rimula Premium 15W40 Shell Rotella T30W Shell Rotella T SAE 30 Shell Rotella T 15W40 SEAL KITS Shell Tellus T46 Oil Texaco 10W40 Texaco Code 1831 Power Steering Fluid 11872 Texaco Code 1854 Mercon / Dexron III Texaco Texamatic 7045E Automatic Transmission Fluid Texaco URSA 15W40 code 2109 Union 10W40 Union 15W40 Unocal 46 Power Steering Fluids Unocal Guardol 15W40 Motor Oil US Oil Wide Range Automatic Transmission Fluid Valvoline All-Climate 10W40 Motor Oil Valvoline AW 32 HVI Oil

9 DIAGNOSIS & TROUBLESHOOTING This section of the manual is designed to help the mechanic troubleshoot steering complaints. Used properly the section will assist you in completing a proper and less time consuming diagnosis and repair. You will find sub sections covering diagnosis, troubleshooting, definitions and terms for complaints. To properly repair the problem you must have a clear understanding of the driver’s complaint. The Glossary of Terms and Definitions will help pin point the problem quickly. Locate the complaint in the troubleshooting section and complete all the necessary tests as outlined in the proper section of this manual. Complete the troubleshooting checklist and record your findings. If after completing the diagnosis and repairs found in the Diagnosis and Troubleshooting section of this manual, you are unsure of your findings, contact the Field Service Department of the R. H. Sheppard Co., Inc. at 717-633-4111. When contacting the R. H. Sheppard Co. with a problem be sure to have your completed troubleshooting checklist available. Do not remove the gear until you have completed all procedures to solve your problems. Remember the steering gear is only one part of a total steering system. Many factors outside the steering gear will affect steering performance. D I A G N O S I S & T R O U B L E S H O O T I N G

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Sheppard M-Series Power Steering Service Manual

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