Peugeot 205 Manual
Steering gear - removal and refittingSuspension and steering / Steering gear - removal and refitting
Manual steering gear
1 Chock the rear wheels then jack up the front of the car and support it on axle stands (see “Jacking and vehicle support”). Remove the front roadwheels.
2 Unscrew the track rod end locknuts then use a separator tool to detach the track rod end balljoints from the hub carrier steering arms.
3 Mark the lower column in relation to the pinion on the steering gear.
4 Unscrew and remove the column-to-pinion clamp bolt.
5 Unscrew and remove the two mounting bolts and withdraw the steering gear from one side of the subframe (see illustration).
15.5 Steering gear mounting bolt locations (arrowed)
6 Refitting is a reversal of removal, but tighten all nuts and bolts to the specified torque. On completion, have the front wheel toe setting checked (see Section 21).
Power-assisted steering gear
7 Chock the rear wheels then jack up the front of the car and support it on axle stands (see “Jacking and vehicle support”). Remove the front roadwheels.
8 Prepare a suitable container, then disconnect the fluid pipes from the steering gear, and allow the fluid to drain into the container.
9 Unscrew the track rod end balljoint locknuts, then use a separator tool to detach the track rod end balljoints from the hub carrier steering arms.
10 Mark the lower column in relation to the pinion on the steering gear.
11 Unscrew and remove the column-to-pinion clamp bolt.
12 On manual transmission models, disconnect the three gearchange control rods from the levers on the transmission.
13 Extract the spring clip from the gearchange linkage (see illustration),
15.13 Extract the spring clip (6) from the gearchange linkage
then unclip the transmission selector and engagement rods, and support them in an upright position out of the way, using wire or string.
14 Remove the two steering gear securing bolts, and recover the spacer tubes from the subframe, then disconnect the steering gear pinion from the steering column shaft.
15 Support the front subframe using a trolley jack and interposed block of wood positioned under the subframe crossmember.
16 Remove the four bolts securing the rear of the subframe to the body, and the two nuts or bolts, as applicable, securing the front of the subframe to the body (see illustration). Also remove the nut and bolt from the lower engine mounting.
15.16 Front subframe attachments
9 Rear securing bolts
10 Front securing bolts
11 Lower engine mounting nut
17 Carefully lower the subframe sufficiently to enable removal of the steering gear, ensuring that the subframe is adequately supported.
18 Rotate the steering gear towards the rear of the vehicle, and withdraw the assembly over the rear of the subframe, taking care not to damage the rack bellows.
19 Refitting is a reversal of removal, bearing in mind the following points: a) Ensure that the spacer tubes are fitted to the steering gear securing bolts.
b) Tighten all fixings to the specified torque.
c) Ensure that the marks made on the steering gear pinion and the lower column during removal are aligned.
d) When reconnecting the fluid pipes to the steering gear, the high pressure fluid pipe must be vertical (see illustration).
15.19 Correct refitting of power assisted steering gear
1 High-pressure pipe 3 Column-to-pinion clamp bolt 10 Hose secured with cable tie
e) Secure the hose to the high-pressure fluid pipe using a cable-tie.
f) Check the gearchange mechanism for correct operation after reconnecting the linkages.
g) On completion, bleed the power steering hydraulic system as described in Section 17, and have the front wheel toe setting checked (see Section 21).