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The Testers Manual

2.2 Steering System

Information	Method of Inspection	Reason for rejection
Types of suspension covered This inspection applies to the steering mechanism of all types of front suspension.	A. Free Play 1. With the road wheels on the ground pointing straight ahead, lightly turn the steering wheel left and right as far as possible without moving the road wheels.	1. A point on the rim of the steering wheel moves, without the road wheels moving, for more than a. 75mm for non rack and pinion
		b.)13mm for rack and pinion steering. Note: Where there are several joints between the steering wheel and the rack, movement up to 48mm on a 380mm diameter wheel may be accepted.
Where to inspect
The inspection must be carried out with the vehicle over a pit or on a raised lift.	Check the amount of free play at the circumference of the steering wheel.
Power steering
If power steering is fitted, the engine must be running for all checks requiring steering movement. ATL or OPTL Approved References to the assistants role in this section do not apply. However an NT may use an assistant to aid inspection of components if the NT considers it necessary	Note: Play due to wear or maladjustment must not be confused with apparent play due to the construction of the mechanism, such as caused by the deflection of flexible joints or spring compression in external power steering systems. Note: The steering wheel free play limit is a general rule for standard diameter steering wheels, (380mm). Lower or higher limits should be set with larger or smaller diameter steering wheels.
Access to steering system B. Play Under Load
As well as the underside inspection it may be necessary to open the engine compartment to examine some steering components on some vehicles (eg steering rack mounted on upper part of the bulkhead etc). If power steering is fitted, o the engine must be running, and o care must be taken when inspecting components in the engine compartment.	Play Under Load With the front road wheels on the ground ask the assistant to rock the steering wheel in both directions firmly against resistance, examine the complete steering mechanism. If ATL or OPTL approved: the wheel play detectors should be used in rotational mode for this inspection. Check for a. insecurity of any components	1. a. insecurity of any part fixed to the vehicle structure, eg steering box, rack housing or intermediate drop arm pivot housing
Components enclosed by gaiters
Because dismantling is not permitted, it is accepted that visual examination of some components which are enclosed by protective gaiters will not be possible.	b. relative movement between sector shaft and drop arm c. loose ball pin shanks d. loose track rod end or drag link ends e. weak or broken socket springs f. excessive play in ball joints	b. relative movement between the sector shaft and the drop arm c. a loose ball pin shank d. a loose track rod or drag link end e. a weak or broken socket spring f. excessive play in a ball joint
Steering Joint dust covers
If a steering joint dust cover is split or missing greater care must be taken when resting the joints. If no other defects are found the tester should advise the presenter.	Note: Play must not be regarded as excessive unless it is clear that replacement, repair or adjustment of the component is necessary
Types of movement
Relative movement due to excessive wear MUST be distinguished from relative movement due to built-in clearance or spring loading of a joint.	g. excessive play at pivot points Note: Play must not be regarded as excessive unless it is clear that replacement, repair or adjustment of the component is necessary	g. excessive play in a pivot point (eg an intermediate drop arm)
Bonded joints
These show movement due to elasticity. Slight deterioration is acceptable.	h. relative movement between the steering arm and its fixings i. the condition and security of rear wheel steering components, including front to rear connecting shafts j. if the rear wheel steering is inoperative, check .the position of the rear wheels and .whether it affects the front wheel steering.	h. relative movement between a steering arm and its fixings i. . a rear wheel steering component insecure . excessive play in a rear wheel steering mechanism connection or ball joint . hydraulic fluid leaking from a rear wheel steering system j. Inoperative rear wheel steering where, . the rear wheels are not held substantially in the straight ahead position, or . the front wheel steering is adversely affected.
C. Static Inspection
When to carry out these inspections The Inspections in this sub-section may be carried out at the same time as the inspections in sub-sections 2.2B and 2.2D.	1. With the road wheels on the ground and the steering wheel and system stationary, Check for	1.
	a. wear in the neck of ball pins	a. sharp or deep grooves in the neck of a ball pin
	b. track rod or drag link ends misaligned	b. track or drag link ends seriously misaligned
	c. components fractured, cracked, damaged, excessively corroded or deformed Note: This inspection also applies to rear wheel steering systems including front to rear connecting shafts	c. a component fractured, or cracked, damaged, excessively corroded or deformed so that it is unserviceable
	d. repairs, especially by welding, or evidence that excessive heat has been applied, to steering components or structural members Note: This inspection also applies to rear wheel steering systems including front to rear connecting shafts	d. structural repair by welding to a steering linkage component, or signs of excessive heat having been applied
		Note: Reasons for Rejection c and d also apply to rear wheel steering. An inoperative rear wheel steering system is not a reason for rejection if . The rear wheels are held substantially in a straight ahead position . The front wheel steering is not adversely affected
	e. fluid leakage from a steering damper seal or gland	e. fluid leakage from a steering damper seal or gland to such an extent that it is clear that the seal or gland has failed
	f. the presence and security of retaining and locking devices	f. a retaining or locking device missing or insecure
	Note: Some locking devices are not obvious. In such cases, the vehicle presenter should be informed of any evidence of disturbance or insecurity
	g. excessive corrosion, severe distortion or a fracture in the chassis or integral body attachment area of a main steering component eg steering box or rack, idler arm mounting, etc.	g. deliberate modification which significantly reduces the original strength, excessive corrosion, severe distortion, a fracture or an inadequate repair of a load bearing member or its supporting structure or supporting panelling within 30cm of a steering component mounting, that is, within a �prescribed area�. See Appendix C
D. Lock to Lock Check
Types of suspension covered This sub-section applies to all suspension types. Mote: Vehicles with a beam axle can alternatively be raised from the ground as in Fig 1, page 29, and this inspection carried out at the same time as the inspections in sub-section 2-5a.	D. Lock to Lock Check 1. With the front steered wheels resting on turning plates, ask the assistant to turn the wheels from lock to lock using the steering wheel. It is important that this inspection is carried out . with the suspension substantially in the normal running position . on vehicles not fitted with a beam axle with the steered wheels resting on turning plates that move freely. Check for a. fouling, particularly brake hoses b. brake hoses or brake pipes stretched or twisted c. security and correct adjustment of lock stops if fitted Note: Some vehicles have lock stops comprising soft metal pads on the body for the front tyres to rub against. These are acceptable if they are properly maintained so that they do not damage the tyres. d. condition and security of steering rack gaiters Note: Expand steering rack gaiters for proper examination e. tightness or roughness in the steering mechanism.	1a. a component of the steering mechanism, road wheels or tyres fouling any part of the vehicle b. a brake pipe or brake hose stretched, twisted or seriously damaged c. . an incorrectly adjusted lock stop . a loose, damaged or insecurely locked lock stop d. an insecure, split or missing steering rack gaiter e. excessive tightness or roughness in the steering mechanism
Issue Date 10th January 2005

The Testers Manual

2.2 Steering System

Information

Method of Inspection

Reason for rejection

Types of suspension covered

This inspection applies to the steering mechanism of all types of front suspension.

A. Free Play

1. With the road wheels on the ground pointing straight ahead, lightly turn the steering wheel left and right as far as possible without moving the road wheels.

1. A point on the rim of the steering wheel moves, without the road wheels moving, for more than

a. 75mm for non rack and pinion

b.)13mm for rack and pinion steering. Note: Where there are several joints between the steering wheel and the rack, movement up to 48mm on a 380mm diameter wheel may be accepted.

Where to inspect

The inspection must be carried out with the vehicle over a pit or on a raised lift.

Check the amount of free play at the circumference of the steering wheel.

Power steering

If power steering is fitted, the engine must be running for all checks requiring steering movement.

ATL or OPTL Approved References to the assistants role in this section do not apply. However an NT may use an assistant to aid inspection of components if the NT considers it necessary

Note: Play due to wear or maladjustment must not be confused with apparent play due to the construction of the mechanism, such as caused by the deflection of flexible joints or spring compression in external power steering systems.

Note: The steering wheel free play limit is a general rule for standard diameter steering wheels, (380mm). Lower or higher limits should be set with larger or smaller diameter steering wheels.

Access to steering system B. Play Under Load

Play Under Load With the front road wheels on the ground ask the assistant to rock the steering wheel in both directions firmly against resistance, examine the complete steering mechanism.

If ATL or OPTL approved: the wheel play detectors should be used in rotational mode for this inspection.

Check for a. insecurity of any components

1.

a. insecurity of any part fixed to the vehicle structure, eg steering box, rack housing or intermediate drop arm pivot housing

Components enclosed by gaiters

Because dismantling is not permitted, it is accepted that visual examination of some components which are enclosed by protective gaiters will not be possible.

b. relative movement between sector shaft and drop arm c. loose ball pin shanks d. loose track rod end or drag link ends e. weak or broken socket springs f. excessive play in ball joints

b. relative movement between the sector shaft and the drop arm c. a loose ball pin shank d. a loose track rod or drag link end e. a weak or broken socket spring f. excessive play in a ball joint

Steering Joint dust covers

If a steering joint dust cover is split or missing greater care must be taken when resting the joints. If no other defects are found the tester should advise the presenter.

Note: Play must not be regarded as excessive unless it is clear that replacement, repair or adjustment of the component is necessary

Types of movement

Relative movement due to excessive wear MUST be distinguished from relative movement due to built-in clearance or spring loading of a joint.

g. excessive play at pivot points Note: Play must not be regarded as excessive unless it is clear that replacement, repair or adjustment of the component is necessary

g. excessive play in a pivot point (eg an intermediate drop arm)

Bonded joints

These show movement due to elasticity. Slight deterioration is acceptable.

h. relative movement between a steering arm and its fixings i.

C. Static Inspection

When to carry out these inspections

The Inspections in this sub-section may be carried out at the same time as the inspections in sub-sections 2.2B and 2.2D.

1. With the road wheels on the ground and the steering wheel and system stationary, Check for

1.

a. wear in the neck of ball pins

a. sharp or deep grooves in the neck of a ball pin

b. track rod or drag link ends misaligned

b. track or drag link ends seriously misaligned

c. components fractured, cracked, damaged, excessively corroded or deformed

Note: This inspection also applies to rear wheel steering systems including front to rear connecting shafts

c. a component fractured, or cracked, damaged, excessively corroded or deformed so that it is unserviceable

d. repairs, especially by welding, or evidence that excessive heat has been applied, to steering components or structural members Note: This inspection also applies to rear wheel steering systems including front to rear connecting shafts

d. structural repair by welding to a steering linkage component, or signs of excessive heat having been applied

Note: Reasons for Rejection c and d also apply to rear wheel steering. An inoperative rear wheel steering system is not a reason for rejection if

. The rear wheels are held substantially in a straight ahead position

. The front wheel steering is not adversely affected

e. fluid leakage from a steering damper seal or gland

e. fluid leakage from a steering damper seal or gland to such an extent that it is clear that the seal or gland has failed

f. the presence and security of retaining and locking devices

f. a retaining or locking device missing or insecure

Note: Some locking devices are not obvious. In such cases, the vehicle presenter should be informed of any evidence of disturbance or insecurity

g. excessive corrosion, severe distortion or a fracture in the chassis or integral body attachment area of a main steering component eg steering box or rack, idler arm mounting, etc.

D. Lock to Lock Check

Types of suspension covered

This sub-section applies to all suspension types. Mote: Vehicles with a beam axle can alternatively be raised from the ground as in Fig 1, page 29, and this inspection carried out at the same time as the inspections in sub-section 2-5a.

1a. a component of the steering mechanism, road wheels or tyres fouling any part of the vehicle b. a brake pipe or brake hose stretched, twisted or seriously damaged

c.

. an incorrectly adjusted lock stop

. a loose, damaged or insecurely locked lock stop

d. an insecure, split or missing steering rack gaiter

e. excessive tightness or roughness in the steering mechanism

Issue Date 10th January 2005

b.)13mm for rack and pinion steering.

Note: Where there are several joints between the steering wheel and the rack, movement up to 48mm on a 380mm diameter wheel may be accepted.

ATL or OPTL Approved

References to the assistants role in this section do not apply. However an NT may use an assistant to aid inspection of components if the NT considers it necessary

Play Under Load

With the front road wheels on the ground ask the assistant to rock the steering wheel in both directions firmly against resistance, examine the complete steering mechanism.

Check for
a. insecurity of any components

b. relative movement between sector shaft and drop arm
c. loose ball pin shanks
d. loose track rod end or drag link ends
e. weak or broken socket springs
f. excessive play in ball joints

b. relative movement between the sector shaft and the drop arm
c. a loose ball pin shank
d. a loose track rod or drag link end e. a weak or broken socket spring
f. excessive play in a ball joint

g. excessive play at pivot points
Note: Play must not be regarded as excessive unless it is clear that replacement, repair or adjustment of the component is necessary

h. relative movement between a steering arm and its fixings

i.

d. repairs, especially by welding, or evidence that excessive heat has been applied, to steering components or structural members
Note: This inspection also applies to rear wheel steering systems including front to rear connecting shafts

This sub-section applies to all suspension
types.
Mote: Vehicles with a beam axle can alternatively be raised from the ground as in

Fig 1, page 29, and this inspection carried
out at the same time as the inspections in sub-section 2-5a.

1a. a component of the steering mechanism, road wheels or tyres fouling any part of the vehicle
b. a brake pipe or brake hose stretched, twisted or seriously damaged