SERVICE MANUAL NUMBER 28 POWER STEERING …

1 6 APOWER STEERINGSERVICE MANUAL NUMBER 2890-863160--1 JUNE 2003 Page 6A-1 STEERING SYSTEMSS ection 6A - POWER SteeringTable of ContentsParts List6A-2.. Torque Specifications6A-2.. Lubricants / Sealants / Adhesives6A-2.. Special Tools6A-3.. Kent-Moore Tools6A-3.. Description6A-4.. Control Valve6A-4.. POWER STEERING System6A-5.. STEERING Helm and Cable6A-8.. STEERING Cable Specifications6A-9.. Filling and Air Bleeding POWER STEERING System6A-10.. Checking Fluid Level6A-10.. Engine Warm6A-10.. Engine Cold6A-11.. Filling and Bleeding6A-12.. POWER STEERING Assembly6A-13.. Removal6A-13.

2 Installation6A-14.. POWER STEERING System Pressure6A-17.. Pump Pressure Test6A-20.. POWER STEERING Pump6A-22.. Removal6A-22.. Flow Control Valve Servicing6A-23.. Pump Shaft Oil Seal Replacement6A-24.. Disassembly6A-27.. Cleaning And Inspection6A-30.. Reassembly6A-30.. Installation6A-37.. Multiple Sterndrive STEERING Tie BarArrangements6A-39.. Internal POWER STEERING With Internal Tie Bar Only6A-39.. Internal POWER STEERING With Internal and External Tie Bar6A-39.. External POWER Steering6A-39.. External POWER STEERING With Low External Tie Bar6A-39.. Determining Tie Bar Length6A-40.

3 Tie Bar Selection6A-41.. Tie Bar Installation6A-41.. POWER STEERINGSERVICE MANUAL NUMBER 28 Page 6A-290-863160--1 JUNE 2003 Parts NumberPower STEERING Pump Seal Kit1156880441 Obtain from a local GM automotive SpecificationsNOTE: Securely tighten all fasteners not listed cable coupler nut4835 STEERING system pivot bolts3425 POWER STEERING hydraulic hose fittings3123 POWER STEERING pump housing studs4735 Pump flow control valve fitting4735 Tie bar locknut6860 Fitting assembly4735 POWER STEERING pump bolt and nut4130 Lubricants / Sealants / AdhesivesDescriptionWhere UsedPart NumberSpecial Lubricant 101 Clevis pins.

4 STEERING cable end92 802865A1 Special Lubricant 101 Bushings92-802865A1O-ringPower Trim and STEERING FluidEnd plate O-ring92-802880A1gReservoir O-ringsLoctite 277 Tie bar threadsObtain locallyPower Trim and STEERING Fluid92-802880A1 Dexron III Automatic Transmis-sion FluidPower Trim PumpObtain locallyPOWER STEERINGSERVICE MANUAL NUMBER 2890-863160--1 JUNE 2003 Page 6A-3 Special ToolsPulley Pusher Installer73670 Installs the pulley on thepower STEERING STEERING Test Gauge Kit74167 Tests the POWER steeringsystem ToolsKent-Moore Tools, Little MackRoseville, MI 48066 Phone: (313) 774-9500 DescriptionPart NumberPower STEERING Pump Pulley RemoverJ-25034 POWER STEERINGSERVICE MANUAL NUMBER 28 Page 6A-490-863160--1 JUNE 2003 DescriptionNOTE: The POWER STEERING pump and related components covered in this section do notpertain to Mercury MerCruiser liter (496 cid) gasoline engine models or any MercuryMerCruiser or Cummins MerCruiser diesel engine models.

5 For information on these modelsrefer to the appropriate engine SERVICE POWER STEERING system utilizes an engine-driven, vane-type hydraulic pump thatsupplies fluid flow and pressure by means of hoses to a control valve that, in turn, controlsfluid flow and pressure to and from a booster cylinder. Modes make up the basic functionof the POWER STEERING system: 1) neutral mode, 2) left turn mode, and 3) right turn control valve, which is activated by the STEERING cable, controls the STEERING : The following POWER STEERING unit installations are viewed from inside boat, lookingat ValveThe control valve is not serviceable and must be replaced as a complete STEERINGSERVICE MANUAL NUMBER 2890-863160--1 JUNE 2003 Page 6A-5 POWER STEERING System75238abcdefRight turn (Viewing from inside of boat looking at transom)a-Pistonb-Control valvec-Oil coolerd-Pumpe-Relief valvef-Pump housingDescriptionHigh pressureLow pressureInternal System Pressure7929-8618 kPa(1150-1250 psi)483-862 kPa(70-125 psi)

6 POWER STEERINGSERVICE MANUAL NUMBER 28 Page 6A-690-863160--1 JUNE 2003 POWER STEERING System75239abcdfeLeft turn (Viewing from inside of boat looking at transom)a-Pistonb-Control valvec-Oil coolerd-Pumpe-Relief valvef-Pump housingDescriptionHigh pressureLow pressureInternal System Pressure7929-8618 kPa(1150-1250 psi)483-862 kPa(70-125 psi) POWER STEERINGSERVICE MANUAL NUMBER 2890-863160--1 JUNE 2003 Page 6A-7 POWER STEERING System75237abcdfeNeutral (Viewing from inside of boat looking at transom)a-Pistonb-Control valvec-Oil coolerd-Pumpe-Relief valvef-Pump housingDescriptionHigh pressureLow pressureInternal system pressure7929-8618 kPa(1150-1250 psi)483-862 kPa(70-125 psi) POWER STEERINGSERVICE MANUAL NUMBER 28 Page 6A-890-863160--1 JUNE 2003 STEERING Helm and CableThe transom assembly is shipped with the STEERING cable guide tube preset for cables withend dimensions that comply with ABYC standards as outlined in the NMMA certificationhandbook.

7 The STEERING cable coupler nut must also have a means of locking it to the guidetube, as specified in ABYC to use a STEERING cable locking device could cause loss of STEERING , whichcould cause damage to the boat and/or : All current production Quicksilver RideGuide STEERING cables have a self-lockingcoupler nut and do not require an external locking device. (Other cable manufacturers alsomake cables with self-locking coupler nut.)22060aa-Quicksilver RideGuide STEERING cable self-locking coupler nut (identified bygroove)IMPORTANT: If using a STEERING cable that does not have a self-locking coupler nut,an external locking device such as a locking sleeve must be STEERING cable with improper dimensions is installed, severe damage to transomassembly and/or STEERING system may STEERING cable must be the correct length, particularly when installed in larger Avoid sharp bends, kinks, or loops in Fully extended STEERING cable end dimension must be as STEERINGSERVICE MANUAL NUMBER 2890-863160--1 JUNE 2003 Page 6A-9 STEERING CABLE SPECIFICATIONSIMPORTANT.

8 POWER STEERING pump lugging (squealing) in a hard right turn (againstlock) may mean a STEERING cable has been installed that does not have the nut - 7/8 - 14 UNF - 2B threadb-298 mm (11-3/4 in.) minimumc-Interface mm (1/2 in.) mm (27/64 in.) minimum mm (7/64 in.) minimum mm (5/8 in.) maximum diameter end mm (3/8 in.) mm (3/8 in.) diameter through hole, chamfered each mm (1-3/8 in.) mm (5/8 in.) diameter tubel-Cable travel:-Mid-travel position - mm (16-7/8 in.)-Total travel to be mm (8 in.) minimum, to mm (9 in.) maximum-Travel each side of mid-travel position mm (4 in.)

9 Minimum, mm(4-1/2 in.) maximumPOWER STEERINGSERVICE MANUAL NUMBER 28 Page 6A-1090-863160--1 JUNE 2003 Filling and Air Bleeding POWER STEERING SystemChecking Fluid LevelENGINE WARM1. Stop engine. Position sterndrive unit so that it is straight Remove fill cap / dipstick from POWER STEERING pump and note fluid cap / dipstickb- POWER STEERING pump3. Level should be between the FULL HOT mark and ADD mark on fluid level with engine warm4. If level is below ADD mark, but fluid is still visible in pump reservoir, add required amountof fluid through fill cap opening, to bring level up to FULL HOT mark on dipstick.

10 DO UsedPart NumberPower Trim and STEERING Fluid92-802880A1 Dexron III Automatic Transmis-sion FluidPower Trim PumpObtain locally5. If fluid is not visible in reservoir, a leak exists in the POWER STEERING system. Find causeand STEERINGSERVICE MANUAL NUMBER 2890-863160--1 JUNE 2003 Page 6A-11 ENGINE COLD1. With engine stopped, position sterndrive unit so that it is straight Remove fill cap / dipstick from POWER STEERING pump and note fluid Level should be between FULL COLD mark and bottom of fluid level with engine cold4. If level is below bottom of dipstick, but fluid is still visible in pump reservoir, add requiredamount of fluid, through fill cap opening, to bring level up to FULL COLD mark ondipstick.