Remanufactured Steering - Repco Trade

1 RemanufacturedSteeringProduct GuideWhatanAUTOSTORE oughttobePhone:133 SteeringProduct GuideContentsFeatures & BenefitsRemoval & Installation TipsTrouble ShootingSystem Noise Identification5710114 Warranty InformationFast track your orders online with Repco Navigator PolicyQuality CertificationRepco provides a two-year, 40,000 KM warranty on ourproduct range. Our low warranty rate of for legitimatewarranties, is a source of great pride to our supplier and isindicative of the commitment they have to producing qualityproducts. A labour claim plus wheel alignment will bere-imbursed to the person undertaking the removal and refitof the unit. Before any work is undertaken it is expected thatthe branch or Trade customer will contact our supplier stechnical department on ournumber so thatthey can assist in advising as to whether it is in fact awarranty claim suppliers and Steering products have been accredited tothe following certification:ISO 9001 : 2008 Management 4801 : 2001 Occupational Health and SafetyManagement 4001 : 2004 Environmental Management most recent External Audit of the three systems wasundertaken in March final paragraph in the Auditor's report is testament to theoutcome:"There were no Corrective Action Reports raised at this fully integrated system is operating satisfactorily.

2 "1800 023 976 Warranty InformationPhone:133 & Benefits5 Repco Power Steering Racks, Boxes and Pumps areremanufactured not reconditioned, and each part number(unit) endures a mandatory quality check and is fitted with thelatest Steering Pumps and SteeringRacks are fully Remanufactured and thoroughly testedto meet the OE manufacturer s designated high risk parts are replaced with newparts whether worn or electronic controlled Steering racks come fittedwith new modulating valve and/or pump applications are supplied with a powersteering suction used in theremanufacturing Steering gear must pass a minimum of fiveseparate tests to attain OE componentsFeatures & BenefitsProduct DifferentiationReconditioningThere is a significant difference between the reconditioningof a Steering gear and the complete remanufacturing of asteering gear. Our supplier sets a standard forremanufacturing Steering gears that no other.

3 Allconsumables must be replaced if a minimum standard ofquality is to be company that reconditions a Steering gear will locate theproblem a leaking pinion seal or power chamber seal,replace that component then adjust the gear to remove anyobvious movement or slack in the centre position in thesteering company has been able to emulateRepco Remanufacturing Means-Gears are completely tie rods, boots and seals are teflon seals are removed and pinion and valve assembly is dismantled rack and also pinion, valve and sleeve assemblyare tested and discarded if cracks are are-All bent and damaged components are , tie rods and boots are replaced withquality the pinion shows excessive wear, pitting or iscracked, it is gear is tested for leaking, attainment of correctpressure between chambers, returnability andelimination of light / heavy to OE genuine OE standardteflonProduct Development / SupportRepco is continually adding new products to the range withnew applications added each month.

4 Each time we are askedto service a unit we do not have in our system, we add thatpart number to our catalogue. We are continually investing innew product for the benefit of our new vehicle models come onto the market, we ensurewe have those units in our system before the vehicle model isout of new car is extensive investment on tooling, test rigs etc eachtime new models are introduced. New tools requiremanufacturing or purchasing to ensure correct processes areperformed in the re-manufacture of each new model. Thisprocess of continual addition of new tooling and fixturesensures that all new additions to the range have the samelevel of comprehensive testing as all existing part SteeringProduct GuideFast track your orders online with Repco Navigator :133 AddingIn Line FilterReturn Line HoseModulating Valves for Variatronic SteeringGearsIdle Up SwitchRepco supply a Magnefine Return Line Filter with all PowerSteering Racks and Power Steering Boxes.

5 This enables thefiltering out of microscopic metal particles which causeconstant wear not only to the pumps but also to the othercomponents such as bearing surfaces, seals, valve and pinionetc. Fitting a filter has proven to reduce the likelihood ofwarranty claims due to RNSP1844 and RNSP1845 (Commodore VS-VY) powersteering pumps are supplied with a new Return Line value adding precludes any perceived warranties due tothe use of the pre-existing worn out Ford & Holden power Steering gears are fitted and testedwith modulating valves that are essential to the performanceof the Ford gears from EA to AU are fitted with a new genuineIdle Up Switch. Again, this is vital to the performance of line FilterReturn Line HoseModulating ValvesIdle Up SwitchFeatures & Benefits6 Fast track your orders online with Repco Navigator tips are intended only to provide assistance to suitablyqualified and trained technicians, and should not be attemptedby unqualified and untrained Power Steering SystemsAir :a)b)c)d)56 Caution:Fill reservoir to cold engine and run for one or two seconds to up reservoir to cold step 2 and 3 until reservoir remains engine idling turn the Steering wheel from left lock toright lock several times lightly touching full lock either engine and top up pumps can develop air locks and will fail tocirculate fluid at initial start up.

6 To simply overcome thisproblem:Start engine and leave at reservoir inlet withone hand and place air gunbetween webbing ofthumb / index fingerthus creating a seal(see Fig: 1)Apply light air pressure for30 seconds to displace airtrapped within pump bodyor till pump up reservoir to coldlevel then refer Steps& .If the vehicle is fitted with an SRS (air bag), asteering wheel clamp must be fitted to the Steering wheel inthe straight ahead position (and the ignition key removed asan added measure to engage the Steering lock) locking thesteering column. If this procedure is not carried out and thesteering wheel is spun while the Steering rack is removed, theclock spring on the upper end of the Steering column will bedestroyed, causing non-deployment of the air bag! (Refer tovehicle service manual).Speed sensitive power Steering - resetting the body controlmodule (BCM) Commodore / Calais / Statesman 10/91 -Speed sensitive power Steering provides the driver withmaximum assistance at low speeds and gradually reduces theassistance as the vehicle speed increases.

7 When a steeringrack is replaced or the wiring loom disconnected, you will needto reset the BCM to restore the Steering back to normaloperating and New DamperContaminated Power SteeringPump HousingBlocked Modulating ValveFollow this simple procedure to reset the BCM:a) Switch off the ) Remove fuse for approx. 3 seconds. (Located in enginecompartment relay housing).c) Refit the fuse, the BCM should ) The vehicle indicators or interior lighting will flash toindicate resetting has been sensing Steering racks contain a plasticdamper, which over time deteriorates and crumbles, spreadingcontaminants throughout the hydraulic system. Whenreplacing a speed sensitive rack, it is recommended to flushall lines and inspect the old modulating valve for evidence ofplastic contamination. This will identify if both power steeringrack and pump are contaminated and require to do so may effect the total hydraulic system within ashort period of time and may void Note: Repco Remanufactured Speed Sensitive Steering Racks haveall springs and dampers replaced as a matter of course, thevalve is retrimmed and a new modulating valve is fitted.

8 Thevehicle should now have full power Calais & StatesmanFuse F21VR to VS Calais & StatesmanFuse F23VT to VX Calais & StatesmanFuse F31 BCM Fuse IdentificationFig: 1 Removal & Installation TipsRemanufactured SteeringProduct Guide7 Phone:133 :When either of the Power Steering units are replacedyou should always inspect the rack modulating valve and thepump flow control valve as it is common for broken pieces ofthe upper pinion damper to become lodged in either or both ofthese components which may cause the system tomalfunction. The symptoms are intermittent, partial or totalloss of power connecting the hose barrel nuts to any die-cast rackhousing, extreme care must be taken not to cross thread orover tighten, as this will damage the housing and cannot berepaired. It could also include a penalty of your core depositas in most instances the housing is not available as aseparate component, and replacement costs are racks use a nitrile seal on the hose connection so it's notnecessary to over tighten the barrel nut to obtain a good a general rule it is best to start barrel nuts with your fingersthen torque fittings to no greater than 25 to installing check the following:-Upper strut bearings and mounting places(for wear or binding).

9 -Bottom ball tie rod are both static and dynamicperformance tested. Any binding in the above areas willincrease the Steering effort above working tie rod end lock nuts. (Count the number of turnswhen removing from old unit).-Fit tie rod ends. (If in any doubt about the condition of theold tie rod ends replace with new).-Centralise rack assembly and Steering wheel spokeNote:Power Racks With Aluminium PinionHousingsCommodore VL-VE & Falcon / FairlaneEA-EL Variable Ratio Power SteeringRacksInstallation-Connect hoses to rack. DO NOT over tighten barrelnuts and ALWAYS replace seals. New seals aresupplied with Exchange Units.: while hoses are disconnected from the rack, careshould be taken to prevent any dirt from entering the systemas this will cause the pump flow control valve to stick which inturn will lead to lack of assistance at tie rod ends to the Steering arms making surethat the split pins are re-inserted in the castellated the reservoir with fluid and bleed according tomanufacturers instructions.

10 To avoid aerating the fluidDO NOT rev the engine during the start up or during thebleeding procedure. If the fluid does become aerated,switch the engine off and let the vehicle stand for an hourto allow the aeration to the toe-in to manufacturers specifications andrecheck the system for oil not turn the Steering wheel without the motorrunning as this can dislodge inner rack seals causing fluid toleak into the all worn hoses can be detected from an outwardinspection, as they deteriorate from the inside out. Steelbraided hoses can create groaning noises and vibrations atlock. OE manufacturers use nylon braided rubber hoses toabsorb the pulses in the fluid that cause vibration. Most OEhoses also have an internally fitted vibration damper toprevent pulsation. Unless the vehicle is a late model or haslow kilometres travelled, all hoses should be fitted to vehicles up to the early 80's used brass oraluminium olives in the connecting fittings to seal the joint, andthereafter using Teflon seal or nitrile o'ring is important that the seals are replaced whenever theconnected fittings are disturbed.