Troubleshooting

Note: This procedure is for new and remanufactured gears from Power Steer Inc. or your vehicle manufacturer. All steering gears from Power Steer Inc. have had their poppett/plunger seats replaced and reset.

Caution: System must be flushed prior to installing new gear. This will ensure any debris or foreign matter that is in system does not damage your new gear.

	Inspect axle stop bolts to ensure they are set to vehicle manufactures wheel cut or clearance specifications.
	Jack up front end so tires are off the ground
	Start engine and let it idle
	Turn steering wheel to full left until you contact axle stop. Pull hard on the wheel.
	Now turn full right until you contact axle stops. Pull hard on the steering wheel.
	Turn vehicle off

When replacing PUMP only :

	Lift front axle off the ground and support with axle stands. Be sure and block rear tires.
	Install pump. Do not reconnect return line from gear to reservoir, rather place hose into a five gallon bucket. Use a plug on reservoir to contain fluid.
	Select proper fluid as recommended for steering gear or linkage system. Note: A good rule of thumb is to use twice the amount of fluid as the capacity of entire system.
	When possible, disconnect the ignition so the engine won’t start. An assistant is required to crank over the engine and to rotate steering wheel at same time. Caution: Avoid hitting or holding against axle stop or damage will occur. At the same time fill reservoir with fluid and make attempt at not letting the pump run dry, this can be difficult at best. This allows the valve to open and the piston to force clean fluid through the pressure hose, valve, piston area and out of the return hose into five gallon container. Flush until clean fluid comes out.
	Now re-attach return line to reservoir, top off reservoir, re-connect ignition system start engine and move wheel to one side. Stop engine and re-inspect fluid. Caution: Don not over fill!
	Start engine and turn steering wheel stop to stop approximately 6 times. Let run until system is at running temp and repeat turning steering wheel stop to stop six times. Caution: Don not hold against axle stops. Note: Many steering systems have additional procedures for bleeding, may need to use manual bleed procedure. Determine gear type to see if has manual bleed screw to get any residual air out of system.
	Start engine and turn steering wheel stop to stop approximately 6 times. Let run until system is at running temp and repeat turning steering wheel stop to stop six times. Caution: Do not hold against axle stops. Note: Many steering systems have additional procedures for bleeding, may need to use manual bleed procedure. Determine gear type to see if has manual bleed screw to get any residual air out of system.

When replacing GEAR only :

	Lift front axle off the ground and support with axle stands. Be sure and block rear tires.
	Install gear. Do not connect pressure and return hoses. Place pressure hose into five gallon container.
	Select proper fluid as recommended for steering gear or linkage system. Note: A good rule of thumb is to use twice the amount of fluid as the capacity of entire system.
	When possible, disconnect the ignition so the engine won’t start. An assistant is required to crank over the engine and to rotate steering wheel at same time.  Caution: Avoid hitting or holding against axle stop or damage will occur. At the same time fill reservoir with fluid and make attempt at not letting the pump run dry, this can be difficult at best. This will allow the valve to open and the piston to force clean fluid through the pressure hose. Flush until clean fluid comes out.
	Remove return hose from reservoir, clean with solvent and air blow dry. Reinstall.
	After re-connecting hoses, fill reservoir and crank over engine 5 seconds. Now turn steering wheel stop to stop without cranking engine. Top off reservoir.
	Start engine and turn steering wheel stop to stop approximately 6 times. Let run until system is at running temp and repeat turning steering wheel stop to stop six times. Caution: Do not hold against axle stops. Note: Many steering systems have additional procedures for bleeding, may need to use manual bleed procedure. Determine gear type to see if has manual bleed screw to get any residual air out of system.
	Lower to ground and inspect fluid level.

Note: If this is a replacement steering gear, please follow the poppett/plunger adjustment procedure for automatic adjusting steering gears prior to bleeding system.

Caution: For Steps 1 and 2 do not turn steering wheel or air may be induced into system.

Step1 : Fill reservoir to nearly full. Crank the engine for 10 seconds without allowing it to start. If it does start, shut off immediately. Check and refill the reservoir. Repeat process at least three times, checking the reservoir each time.

Caution: Do not allow fluid to drop significantly or run out of reservoir as this may induce air into system.

Step2 : Start engine and let it idle for two minutes. Do not steer. Shut off engine and check the reservoir fluid level. Refill if necessary.

Step3 : Start the engine again. Steer the vehicle from full left to full right several times. Add fluid, as necessary to full line on dipstick.

Note: The above procedure should remove all air from steering system. If gear is mounted in an inverted position and is equipped with a manual bleed screw, commonly found with TRW/Ross steering gears, please continue to step 4.

Step4 : Follow the above procedure. Leave engine idling. With the steering gear in centered position, loosen the bleed screw about one turn (5/16 inch socket required for TRW/Ross, 1/8” allen wrench for Sheppard ). This allows the air and aerated fluid to “bleed out” around bleed screw until only clear (non aerated) fluid is present. Close bleed screw and check and fill reservoir if necessary. Torque manual bleed screw to
27-33 inch pounds.

Caution: Do not turn steering wheel with manual bleed screw loosened.

Bleeding the dual steering gear system is necessary whenever the system has been repaired. The bleeding procedure is the same no matter the gear sizes used.

	Raise the vehicle up until front wheels have cleared surface.
	Inspect fluid level in reservoir to ensure it is full. Continue filling after starting engine and during the bleed process to maintain correct fluid level. Note: Do not allow reservoir to empty during this procedure as it can cause pump damage or further aeration.
	Remove drag links from both master and slave gears pitman arm following the procedure in vehicles service manual.
	Start engine and allow it to idle.
	Turn steering wheel to full left and hold until slave gear moves its full travel. Then turn full right and hold until slave gear moves its full travel. Repeat this three or more times.
	Connect drag link to the master gear. Torque attaching nut according to vehicle service manual. Note: Do not back off nut while finding cotter pin hole. Note: Always use new cotter pins, retainers or fasteners.
	Install new cotter pin through ball stud nut and lock in place. Note: Not installing a new cotter pin in ball stud could result in loss of steering control.
	With the master gear drag link connected, turn the steering wheel too full left turn and hold until slave gear pitman arm reaches full travel. Then turn the steering wheel to full right turn and hold until slave gear pitman reaches full travel. Repeat this three or more times.
	Connect the drag link to the slave gear, turn steering wheel until pitman arm lines up with drag link. (Do not move the pitman arm by hand as air may get into system.) Torque attaching nut according to vehicle service manual.
	Install new cotter pin through ball stud nut and lock in place.
	Turn full left and full right several more times.
	Inspect fluid level.