User manual BENDIX COMPACT 500

[. . . ] ® COMPACT 500 INTEGRAL HYDRAULIC POWER STEERING GEAR FOR FORD MOTOR CO. DESCRIPTION The Compact 500 Hydraulic Power Steering gear is designed for heavy duty vehicles with front axle weight ratings of up to 15, 000 lbs. It is an integral power steering gear incorporating the mechanical and hydraulic actuation and control components in a single cast housing which serves as the power cylinder. The vehicles steering column is coupled to the gear at the input shaft which transmits steering effort through a recirculating ball screw and piston nut. [. . . ] Exterior of spindle and interior of piston and recirculating balls. NOTE: Minor scuffing of the piston exterior and housing bore can be considered normal. If deep scoring is detected, the affected parts should be replaced as leakage will occur and steering control and reaction will be affected. Do not attempt honing or boring of these parts as leakage rates will increase. Parts found broken, cracked, distorted or fatigued must be replaced. Cause for the replacement of any part should be investigated and corrected to prevent reoccurrence. 36 35 37 38 IX. REASSEMBLING THE POWER STEERING UNIT To ensure a correct fault-free operation of the power steering unit, after all parts have been cleaned and faulty ones replaced, the following assembly procedure should be followed. The appropriate maintenance kit or kits should be obtained prior to assembly. Should any of the 17 ball bearing balls require replacement, replace them all at once; proceed similarly in case any of the 26 recirculating balls need replacement. Failure to follow this procedure strictly may result in a faulty operation of the power steering unit. FIGURE 29 16 33 16 12 10 9 11 8 7 6 5 4 3 28 34 FIGURE 30 30 29 16 VALVE BODY (REFER TO FIGURE 30) 1. Place the valve body(16) in a vise and lightly tighten on the cast surface. Install the ball(12), spring(11) valve seat(9) and the copper/seal washer(10). Tighten with an appropriate screwdriver to a torque of 200 in. (See Figure 30) NOTE: A new copper washer(4) must be used to assure correct sealing. Install the relief valve rod(8), the guide(7) and the spring(6). Place the copper seal washer(4) onto the plug(3) with the corresponding adjusting shims(5) and tighten with 26 mm. Install the seal(15), snap ring(14), and dust seal(13) into valve body(16). Using tool number 297647, install the inner ball race(28) (in the event it was removed), into the bottom of valve body and install internal O-Ring(17) and the two external O-Rings(19). Install nylon seal(18) in 13 14 15 16 FIGURE 33 the internal threaded portion of the valve body(16). Install the cage(30) on the input shaft end of the spindle(34). Install the outer ball race(28) and using a lithium base general purpose grease (Ford Chassis grease ESA-M1C75-B) to hold them in place insert the 17 new balls(29) comprising the bearing. Insert the assembly into the valve body. [. . . ] Excessive free play in steering wheel. A. Power steering housing or housing support loose. Excessive play between output shaft sector teeth and piston. Loose or worn ball studs in steering linkage. [. . . ]