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5. Ploce
the steering
box with its bottom
boll
beoring resting on the MP 7-102 jig
ond press
the steering screw
with both beorings into the
iig. Extroct the
bottom beoring using
the MP
6-111 king pin
socket remover
ond push
the
steening screw with the top beoring oert of the
steering box. Support the beoring by the Mp
7-102 iig crnd
press
it out.
7.3 REASSEMBLING STEERING BOX
1. Press the dust cup with its seoling
ring
into the steering
box with the pressed-in
bush
ofter hoving thorouchly
cleorred the box. Now
pf oce the box on the MP 7-102
iig oncl
press-in
the bottom boll beorinct
using tlrei pressing
mandrel MP 7-103.
2. Fit the lower beoring
cop seoled
off with
o poper
gcsket
ond seoling compound, slip
lpring woshers
on to the bolts,
ond tighten the
bolts with o torque os per
Chopter t.6. f it the
wosher on the steering screw
with its deflec-
tion focing
the screw threod ond press
the
top beoring on the screw
using the Mp Z-103
pressing mondrel.
3. Then ploce
ogoin the steering box on the
MP7-102 iig ond
press
into it ond into the bot-
tom beoring the steering
screw with the pnessed-
-on top boll beoring,
using ogoin
the Mp7-103
pressing mondrel. For further ossembly, use the
vice ond the dummy brocket.
Fig. 7.311 -
Pressing-in Bottom
Beoring
on MP 7-102
Jig (support
plote)
Using
MP 7-103 Piressinq
Mondrel 4.
Meosure the height of the beoring pro-
truding from the steering box ond odiust it by
fitting shims interspoced with poper goskets
cooted with o seoling
compound.
Fosten down
the cop by tightening the bolts. Check the
steering screw for free rototion
ond the obsence
of ploy.
The beoring should be without o cleor-
once or there hos
to be o prestress
of up to
0.07 mm.
5. Remove the bolts of the cop, slip the rub-
ber seoling ring dipped in oil on to the shoft,
ond fit the dust cup on the cop. lnstoll spring
woshers on the bolts. Should the cup be over-
stroined due to the toleronce
of the recess for
the seoling ring or the ring itself
, instoll
o poper
gosket under it os under tlre ccrp.
6. Locote the steering nut on the screw fol-
lowecl by the rocker shoft with pin, spring,
spring pin, ond the licl gosket
cooted with
o seoling compound, ond fit the lid with bush
in position to close the steering
box. Instoll
spring woshers under the bolts orrd tighten the
bolts with o torque os per
Chopter 1.8. Screw
the set screw into the lid ond rnove
the steer-
ing geor
so thot the drop orrn is swivelled
through obout one holf of its trovel from the one
or the other extreme lock position.
Witlr the
drop ornr in this position,
screw down the set
screw os for os it will go
ond then bock it off
through obout 95 to '120'.
This will provide
for
on odequote cleoronce of the steering geor.
[.ock the set screw in position
with the re-
spective nut.
7. Drive the key on to the rocker shoft cone,
fit the drop orm ond hold it down lightly with
the nut. Clomp the drop orm in o vice, tighten
fully the nut (for
the tightening torque see
Chopter 1.8), ond secure tlre nut with o cotter
pi n.
8. Clomp ogoin the steering box by meons of
the dummy brocket ond moke sure
thot the dnop
orm con swivel from one extreme lock position
to the other. A certoin
resistonce should olwoys
be present,
but if the resistonce is too greot,
decreose it by o slight slockening of the set
screw in the lid. The
rototing resistonce of the
shaft should not exceed 20 Nm (O.2
kpm). Refer to
page 117/118 for testing
procedure.
9. Set the ossembled steering box in its fit-
ting position
(inclined
by obout 40o) ond pour
in oil through the hole in the bbx lid (cover)
till the oil level reoches the bottom edge of the
filling hole. Then
screw down the topered plug.
7.4 RELAY (TDLER)
LEVER
For its instollotion (ond
removing in reverse
order) ond ony pertinent porticulors
see the
Chopter 6.5, porogrophs
2 ond 3.
122

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7
.7-1.8
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b
tl
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tl
p
odiust,
if necessory, the driving dog of the di-
rection indicotor switch -
see Chopter 13.17.
Refit the steering wheel so thot its spokes
ore horizontol, lock it in position
with the nut
(for tightening torque, see
Chopter 1.8), ond
bolt down the spoke shroud.
7.8 STEERING WHEEL SHAFT AND SHAFT
BEARING
The steering wheel (column) shoft is built
up
of two ports
with the beoring in the uPPer port.
Usuolly, it is not necessory to disconnect the
two ports
of the shoft or to remove the beoring
ond steering lock. lt
con be removed from the
cor os o unit.
Removol 1. Remove the steering wheel -
see Chop-
ter 7.7. 2. Remove the screws on the lower port
of
the shoft cowling ond pull
the cowling off.After
removing two bolts, detoch the cluster switch
on the shoft from the upper port
of the shoft
cowling. 3. Remove two front screws of the upper
Port
of the cowling ond remove the cowling.
4. Disconnect the leods
from the switches
ond the switch box.
5. From under the cor, remove the bolt of the
coupling connecting the steering
column shoft
to the steering box ond detoch the dust boot
from the floor. Remove the
bolts of the shoft
beoring (from
under the shoft)
ond the bolts of
the steering lock (from
the front) fostening the
shoft to the body, ond pull
out the shoft.
Ref itting To ref it the steering column shoft
in the cor,
reverse the removing procedure. While reinstol-
ling the steering wheel (Chopter
7.7), do not
forget to check the direction indicotor switch
for correct function.
Use ploin
ond spring woshers under the bolts
of the steering lock
brocket. Reinstoll the shoft
beoring using spocing tubes, rubber bushes, ond
ploin woshers, ond secure the bolt of
the coup-
ling, connecting the steering
column shoft with
the steering box, with
o self-locking nut (for
tightening torque, see
Chopter 1.8).
To Disconnect Shofts
Remove the bolt
of the cross-pin
ioint con-
nection.
Connecting of Shofts
Fit o fostening sleeve on the tube
with the
shoft, dip the ring in oil ond slip
it on to the shoft end with
its wedge-shoped port
toword
the beoring, instoll the spring
ond the
ioint
socket of
the shoft bottom port.
Tighten
the
connection with the bolt with self-locking
nut
(tightening torque os per
Chopter 1.8).
The sleeve must be f irst built up if
the shoft
is refitted for the first time. Locote
both holves
of the sleeve on the tube ond fosten
them
lightly together by bending the tob of one holf
of ttre sleeve over the
other. The
sleeve must
on no occount clomp the tube tightly.
Bottom Port of Steering
Column Shoft
The shoft is provided
with cross-pin
ioints
ond connot be dismontled (token
oport). Before
fitting the shoft dust boot, smeor
it with
oil to
focilitote its slipping over the pcrrts
of the joint.
For this purpose,
it is clso odvisoble to wrop
the joint
in o plostic
foil or to moke o sleeve
with o pilot
cone.
Top Port of Steering Column
Shoft -
Beoring
Removol 1. l-ift owoy the fostening sleeve
ond check
whether the shoft rototes
freely in the tube. lf
it is not the cose, unlock the steering lock ond
press out the shoft proceedirrg
from the side
of its splined
end.
2. lf necessory, remove
the circlip of the shoft
ond lift owoy the beoring. The other beoring
hos to be driven out by topping it corefully
through the cut-outs in
the tube to ovoid domog-
ing it. 3. Remove the brocket with the steering
lock
- see Chopter 7.9.
Ref itting
1. Slip tlre beoring pocked
with greose
on to
the upper port
of the shoft, then the ring with
its wedge-shoped port
focing the beoring, ond
lock both ports
in position
with the circlip.
Press the shoft into the tube ond press-in
the
beoring (ogoin pocked
with greose)
from the
other end.
2. lnstoll the brocket with the steering lock -
see Chopter 7.9.
Shoft Beorings They hove to be thoroughly lubricoted
first,
since ofter their reossembly with the shoft od-
ditionol lubricotion is not possible.
lf there is
ony doubt concerning the greose
pocking,
re-
move the circlip f
rom the inner port
of the
beoring, toke the beoring oport, cleon it, ond
reossemble it ofter hoving pocked
it with the
recommended greose,
i. e., brond NH2 of Cze-
choslovok provenience
or one of the bronds
specif ied in Chopter 7.5, porogroph
3.
124

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I
I
T
!
(
(
t I
t
t
t I
'l
(
r
o cc
fold
ot the moment of
the opplicotion of the
brokes, ond led
through o rubber hose (tube)
to
the booster.
Removol ond Refitting
The broke booster is held down on the pedol
brocket by nuts ond spring
woshers. The lug of
the control volve press
button connects it with
the broke pedol,
on which it is secured by o re-
toining ring. These
mounting ports
or the con-
nections of the vocuum supply
ore to be hondl-
ed only when removing
or refitting the broke
booster.
However, we odvise you
to hove this
iob done
in o speciolized
repoir shop properly
instructed
by the broke
monufocturer. All rubber ports (in
the terms of current mointenonce,
this is
procticolly the seol of the press
button control-
ling the moster cylinder)
must be protected
from the effects of the broke fluid or other
lubriconts. Use petrol
for cleoning the rubben
ports.
Adiustment 1. Adiust the cleononce
between the broke
booster press
button ond the cylinder piston
whenever the moster
cylinder or the'broke
booster ore reploced,
or whenever there is ony
doubt concerning
the correctness
of the os-
sembly of the moster cylinder
with the broke
booster. Meosure the distonce between the
cylinder bottom recess
ond the cylinder flonge
nroting surfoce os well os the length of the
press button protruding
over the moting surfoce
of the booster.
Compore the meosurings
ond
odiust the length of the press
button by rototing
its threoded
end to obtoin o cleoronce of 0.5 to
1 mm between the press
button ond the piston.
Still better, you
can use special
tools Mp6.
'14'lA.
Fit it on the
moster cylinder, push
its spindle into the cylinder till its rounded
end
rests ogoinst
the piston,
ond lock it in this po-
sitio-n with the respective
retoining screw.
Apply
the fixture to the booster
ond rotote the boostei press
button so thot it
iust touches the
lower
flot port
of the fixture spindle.
2. lf it is necessory
to level
the broke pedol
with the clutch pedol,
odiust the length
of the
contnol volve press
button lug.
Remove the broke
booster from the pedol
brocket, slip off the collor (cup),
connect the
booster with the pedol,
ond refit it tempororily
to the brocket.
Now rotote the hexogon on the
threods of the lug till both the clutch ond broke
pedol ore level. Remove once more the booster
from the pedol
ond pedol
brocket, neinstoll the
collor (cup),
ond complete the f inol reossembly.
9.7 BRAKE FLUID TANK, PIPING AND HOSES
Tonk ond Filling Hose
The broke fluid tonk is held in position
in its
brocket by o slip-over
clomp. Speciol rubber
hoses connect it with the broke ond clutch
moster cylinders.
Hose clips ore used to secure
the hoses on the tonk outlet sockets.
Both the
side ond centre outlet of the tonk ore con-
nected to the bnoke moster cylinder, the third
outlet being connected to the clutch moster
cylinder (see Fig. 12.111).
Pressure Piping ond Hoses
The rigid port
of the hydroulic line consists
of speciol steel pipes.
Their connections with
other ports of the line ore seoled off by clomp-
ing on the conicol surfoces-
lf these conicol surfoces
become domoged,
remove them ond form new ones by floring the
pipes. To do this, use the coulking holder,
type
MP 9-151. Clomp the pipe
in the holder so thot
it is level with its upper edge ond flore the pipe
with c coulking chisel. The holder is designed
to be clomped in o vice.
The holder
hos two drilled holes of 5 ond
6 mm in diometer so thot it con be used olso for
repoirs of pipes
of the clutch line. For dio.
5 mm holes, use the MP 9-152 ond for dio. 6 mm
holes, the MP 9-153 coulking chisel.
The flexiblepqrt
of the hydroulic line consists
of speciol hoses.
When fitting them to the reor
wheel cylinders, turn them in o position
which
will prevent
their contoct with ony ports
of the
cor in both extreme positions
of the cor sus-
pension. This is why the nipples ot the reor
wheels ore inclined
downword through on
ongle of 30 degrees from
the horizontol plone.
9.8 HAND BRAKE
The hond-broke
lever between the front seots
controls the tie-rod which octuotes the rocker
(see Fig.9.8/1). Cobles connected
to the rocker
Fig. 9.612
-
Broke Booster Press
Button
Adiusting Fixture
MP6 141A tx r5?2
140