TECHNICAL SERVICE BULLETIN Bulletin Number 78/04

Passenger and Light/Medium Commercial Issue Date: 7 October, 2004

Circulate to Service Manager Parts Manager Foreman Receptionist Technicians

NOTE: TSB 78/04 SUPERCEEDES TSB 67/04 – PLEASE DESTROY ALL COPIES OF
TSB 67/04.

Subject/Concern: POWER STEERING GEARS KNOCKS, CLUNKS, CREAK, CLICKING ETC…

Models: All BA Vehicles

Summary
Cause: Knocking / Noisy Steering Gears. (Knocks, Clunks, Graunch, Clicking, etc…).
Action: Follow this TSB to correct the above concern without the need to replace the steering
gear.
Warranty Status: Reimbursable within the provisions of the Warranty and Policy Manual.

Parts Required
Description Part Number Quantity
90° Countersink 3 Flute Cutting Tool (AE Baker / Blackwood’s Part No. Dealer Supply 1
01175132)
0.20mm Stainless Steel Washer BA3S639A 1 Off

Service Procedure
Concern Description:

Approximately 80% of steering gears (racks) replaced under warranty for the above concerns have been analyzed,
tested and found to be No Fault Found (NFF).
The following procedure will assist Technicians to determine whether the steering gear (rack) is faulty.
Prior to replacement or repairs of the power steering gear, the following diagnosis information and/or repair
procedure should be followed to determine if the power steering gear is faulty.

Service Action:

KNOCKING / NOISY STEERING GEARS, (KNOCKS, CREAK, CLUNKS, GRAUNCH, CLICKING, TICKING etc…).
Testing and analysis has shown that the main cause for the above knock type noises is dependant on the interface
between the steering gear and the cross member. There are actually 2 causes and they are:

1. Steering gear surface damage.

2. Thread burr on the stud hole in the cross member.

The following procedure will allow technicians to rectify the above concern without the need of replacing the steering
gear (rack).
The following Steps 1 & 2 are to ensure that all relevant hardware are torqued to the correct spec, to rule out any
other hardware type issues and/or wheel bearing concern that can be easily misdiagnosed as steering gear related
issue.

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Step 1

Check Wheel Bearing condition.

Step 2

Check front strut movement / suspension torque / sub frame / cross member mounting bolts.
Please Note: To check the hardware you will be required to back the bolt/nut off by approximately 2 turns
and then re-torque to the correct torque setting. Please refer to the BA workshop manual Volume 1 for
correct torque settings.

- Wheel Bearing Check => Page 100-04-56

- Front Suspension Torque Specifications => Page 204-01-2
- Steering Torque Specifications => Page 211-02-2

Step 3

With Vehicle stationary and not running, check for any noise by rotating the steering wheel from side to side. If a
creak, clicking, ticking, knock type noise is still present then go to step 6.
Please Note: The above checking method provides the highest load onto the steering gear, in particular to
the interface of the steering gear to the cross member that maybe creating the above concern.

Step 4

If no noise is present / heard. Road Test Vehicle to confirm no noise. If Noise is still present then go to step 6.

Step 5

If no noise is present / heard after road test. Then return vehicle back to customer.

Step 6

If a creak, clicking, ticking, knock type noise is still present then you will need to remove the steering gear.
Note: To R & R Steering Gear for vehicles fitted with a V8, please refer to the BA workshop manual section
211-02 page number 211-02-24. You may also find that on an XR fitted with a V8 Engine the left hand side
exhaust flange stud may have to be removed.

Step 7

Using a 90° countersink-cutting tool, apply a 2.0mm x 45° chamfer to the front face of the steering gear. (Ref to Fig
1).
Please Note: The 2.0mm x 45° chamfer provides sufficient clearance for the burr that is caused by the stud
fitment. If chamfer exists on the steering gear then please go to step 8.
NOTE : CHAMFER ALREADY EXSISTS ON VEHICLES ASSEMBLED FROM 1st OF SEPTEMBER 2003.

Step 8

Using a smooth Flat file, lightly file the front mounting face of the steering gear. (Ref to Fig 2). This is to ensure that
the mounting face on the steering gear is free from any burrs and/or other marks.

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Step 9

Clean mating face on 2B Cross Member. Ensuring it is free from any oil, dirt and other contaminants. (Ref to Fig 3).

Step 10

Fit Stainless Steel Washer on Drivers Side Mounting Stud. (Ref to Fig 5).
NOTE : STAINLESS STEEL WASHER ALREADY FITTED TO VEHICLES ASSEMBLED FROM 30th OF JUNE
2004.

Step 11

Re-Fit steering gear. Ensuring that the steering gear mounting bolt nut (Ref to Fig 4) is torqued to 80Nm.
Note: To R & R Steering Gear for vehicles fitted with a V8, please refer to the BA workshop manual section
211-02 page number 211-02-24. You may also find that on an XR fitted with a V8 Engine the left hand side
exhaust flange stud may have to be removed.

WARNING: DO NOT USE AND/OR APPLY LUBRICATION AND/OR GREASE TO THE STUD.

Step 12

With vehicle stationary and not running re-check for any noises by rotating the steering wheel from side to side with
the wheels pointed straight ahead.

Step 13

If a creak, clicking, ticking, knock type noise is still present then replace the steering gear.

Front Face to be
lightly cleaned with
a flat smooth file

2mm chamfer on the

front face of the
steering gear

Figure 1: Figure 2:

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 Front Mounting face Steering Gear
on 2B Crossmember. Mounting bolt nut.
Torque 80Nm.
Steering Gear
Mounting Bolt

Steering Gear
Valve Housing
Cross Member

Figure 3: Figure 4:

Figure 3: Figure 4:

2B Cross Member
0.20mm Thick Stainless Stud.
Steel Washer Fitted on 2B
Cross Member Driver Side
Stud.

0.20mm Thick
Stainless Steel Washer
2B Cross Member

Figure 5

Note: Claims will be scrutinized by WARPEC. No Fault Found (NFF) Claims and/or claims whereby a
wheel alignment has been carried out and no before and after test results (In the claim comments area)
have been submitted with the claim will be denied.

Operation Number/Standard Repair Time

Operation Description Operation Number Time
R & R Steering Gear (Manual Gearbox 6 & V8 Cylinder Engine) TSB 07804 1.00
R & R Steering Gear (Automatic Gearbox 6 & V8 Cylinder Engine) TSB 07804 1.00
Front Toe-in correct (NOTE: Before and after results must be entered 3001A6F 0.20
with claim).
2.0mm x 45° Chamfer on Steering Gear Housing, Clean, and carry out TSB 07804A 0.40
Hardware and Associated Parts Checks.
Road Test (Max. Claimable Allowance) 1000A 0.30

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Repair/Claim Coding
Warranty Claim Causal Condition
Part
Enter 04078 in box "X" of warranty claim to reference this TSB
Fairmont Ghia, V8 Engines, Fairlane, Fairlane Ghia, and 17” Alloys. BA3504B 57 Knocks
All others. BA3504A 57 Knocks

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