INDEX

SERVICE MANUAL NUMBER 14 POWER STEERING

STEERING SYSTEMS
Section 6A - Power Steering
Table of Contents
Trim Pump Specifications . . . . . . . . . . . . 5A-2 Selection . . . . . . . . . . . . . . . . . . . . . . . . 6A-17
Valve Pressure Specifications . . . . . . 5A-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . 6A-18
Specifications . . . . . . . . . . . . . . . . . . . . . . . 6A-2 Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-18
Special Tools . . . . . . . . . . . . . . . . . . . . . 6A-2 Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-20
Lubricants/Adhesives/Sealers . . . . . . 6A-2 Power Steering Pump Lugging Test . 6A-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . 6A-3 Power Steering System Pressure
Earlier Style Control Valve . . . . . . . . . 6A-3 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-23
Later Style Control Valve . . . . . . . . . . 6A-3 Pump Pressure Test . . . . . . . . . . . . . . 6A-25
Earlier Model Power Steering System . . 6A-4 Booster Cylinder Test . . . . . . . . . . . . . 6A-27
Right Turn . . . . . . . . . . . . . . . . . . . . . . . 6A-4 Power Steering Component Repair . . . . 6A-29
Earlier Model Power Steering System . . 6A-5 Power Steering Unit . . . . . . . . . . . . . . . 6A-29
Left Turn . . . . . . . . . . . . . . . . . . . . . . . . 6A-5 Cable Guide Tube (Early Style Only) 6A-33
Earlier Model Power Steering System . . 6A-6 Control Valve (Early Style Only) . . . . 6A-37
Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-6 Booster Cylinder (Early Style Only) . 6A-50
Later Model Power Steering System . . . 6A-7 Power Steering Pump . . . . . . . . . . . . . . . . 6A-55
Right Turn . . . . . . . . . . . . . . . . . . . . . . . 6A-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . 6A-55
Later Model Power Steering System . . . 6A-8 Flow Control Valve Servicing . . . . . . . 6A-55
Left Turn . . . . . . . . . . . . . . . . . . . . . . . .
Later Model Power Steering System . . .
6A-8
6A-9
Pump Shaft Oil Seal Replacement . .
Disassembly . . . . . . . . . . . . . . . . . . . . .
6A-56
6A-58 6
Neutral . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Helm and Cable . . . . . . . . . . . . .
6A-9
6A-10
Cleaning And Inspection . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . .
6A-61
6A-61
A
Steering Cable Specifications . . . . . . 6A-11 Multiple Sterndrive Steering Tie Bar
Filling and Air Bleeding Power Arrangements . . . . . . . . . . . . . . . . . . . 6A-67
Steering System . . . . . . . . . . . . . . . . . . . . 6A-12 Determining Tie Bar Length . . . . . . . . 6A-67
Balancing Power Steering Control Selection . . . . . . . . . . . . . . . . . . . . . . . . 6A-68
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-13 Installation . . . . . . . . . . . . . . . . . . . . . . . 6A-69
Steering Cable Selection, Removal
and Installation . . . . . . . . . . . . . . . . . . . . . 6A-17

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POWER STEERING SERVICE MANUAL NUMBER 14

Specifications
Special Tools
Kent-Moore Special Tools
Kent-Moore Tools, Inc.
29784 Little Mack
Roseville, MI 48066
Phone: (313) 774-9500
Power Steering Pump Pulley Remover J-25034

Snap-On Special Tools

Snap-On Tools
2801 80th Street
Kenosha, WI 53141
See Snap-On Catalog
for your regional distributor phone number.
Serpentine Belt Pulley Remover CJ124A

MerCruiser Special Tools

Mercury Marine
W6250 Pioneer Rd., P.O. Box 1939
Fond Du Lac, WI 54936-1939
Phone: 1-800-487-MERC
Fax: 1-800-457-8736
www.MERCURYMARINE.COM
Power Steering Test Gauge 91-38053A4
Power Steering Pump Pulley Installer 91-93656A1

Lubricants/Adhesives/Sealers
Description Part No.
2-4-C Marine Lubricant with Teflon 92-825407A12
Special Lubricant 101 92-13872A1
Loctite No. 8831 92-826089-1

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SERVICE MANUAL NUMBER 14 POWER STEERING

Description
The Power Steering system utilizes an engine-driven, vane-type hydraulic pump that
supplies fluid flow and pressure by means of hoses to a control valve that, in turn, controls
fluid flow and pressure to-and-from a booster cylinder. Three modes make up the basic
function of the Power Steering system: 1) neutral mode, 2) left turn mode, and 3) right turn
mode. The control valve, which is activated by the steering cable, controls the steering
system modes.
NOTE: The following Power Steering unit installations are viewed from inside boat, looking
at transom.
Earlier Style Control Valve
Most illustrations in this section show an earlier style power steering control valve. This
valve has various components that can be replaced and or serviced.

50912

Later Style Control Valve

The later style control valve is not serviceable and must be replaced as a complete
assembly.

73898

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POWER STEERING SERVICE MANUAL NUMBER 14

Earlier Model Power Steering System

Right Turn

h
f 22213

(VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM)

a - Piston e - Relief Valve

b - Control Valve f - Pump Housing
c - Pump g - High Pressure
d - Power Steering Fluid Cooler h - Low Pressure

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SERVICE MANUAL NUMBER 14 POWER STEERING

Earlier Model Power Steering System

Left Turn

h
f
22215

(VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM)

a - Piston e - Relief Valve

b - Control Valve f - Pump Housing
c - Pump g - High Pressure
d - Power Steering Fluid Cooler h - Low Pressure

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POWER STEERING SERVICE MANUAL NUMBER 14

Earlier Model Power Steering System

Neutral

h
f 22214

(VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM)

a - Piston e - Relief Valve

b - Control Valve f - Pump Housing
c - Pump g - High Pressure
d - Power Steering Fluid Cooler h - Low Pressure

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SERVICE MANUAL NUMBER 14 POWER STEERING

Later Model Power Steering System

Right Turn

75238
g
h
f
(VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM)

a - Piston e - Relief Valve

b - Control Valve f - Pump Housing
c - Pump g - High Pressure
d - Power Steering Fluid Cooler h - Low Pressure

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POWER STEERING SERVICE MANUAL NUMBER 14

Later Model Power Steering System

Left Turn

75239
g
h
f
(VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM)

a - Piston e - Relief Valve

b - Control Valve f - Pump Housing
c - Pump g - High Pressure
d - Power Steering Fluid Cooler h - Low Pressure

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SERVICE MANUAL NUMBER 14 POWER STEERING

Later Model Power Steering System

Neutral

75237

g
f h
(VIEWING FROM INSIDE OF BOAT LOOKING AT TRANSOM)

a - Piston e - Relief Valve

b - Control Valve f - Pump Housing
c - Pump g - High Pressure
d - Power Steering Fluid Cooler h - Low Pressure

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POWER STEERING SERVICE MANUAL NUMBER 14

Steering Helm and Cable

Transom assembly is shipped with the steering cable guide tube preset for cables with end
dimensions that comply with ABYC standards as outlined in the NMMA certification
handbook. The steering cable coupler nut must also have a means of locking it to the guide
tube, as specified in ABYC requirements.

WARNING
Failure to use a steering cable locking device could cause loss of steering, which
could cause damage to the boat and/or injury.

All current production Quicksilver Ride Guide steering cables have a self-locking coupler
nut and do not require an external locking device. (Other cable manufacturers also make
cables with self-locking coupler nut.)
a

22060

a - Quicksilver Ride Guide Steering Cable Self-Locking Coupler Nut (Identified By

Groove)

IMPORTANT: If using a steering cable that does not have a self-locking coupler nut,
an external locking device must be used.
b c

a
50629

Locking Plate
a - Locking Plate P/N 92766
b - Screw P/N 10-41209 - (see “Torque Specifications”)
c - Washer P/N 12-35462

c e
b

a d f
Locking Sleeve
a - Steering Cable
b - Grease Fitting
c - Cotter Pin
d - Locking Sleeve (If Required - Must Be Ordered Separately)
e - Cable Coupler Nut
f - Cable Guide Tube

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SERVICE MANUAL NUMBER 14 POWER STEERING

CAUTION
POWER STEERING EQUIPPED UNITS ONLY - If cables with improper dimensions
are installed, severe damage to transom assembly and/or steering system may re-
sult. DO NOT attempt to adjust cable guide tube on power steering unit, as guide
tube and locknut have been torqued (with Loctite) at the factory, and an attempt to
loosen nut or sleeve may result in damage to tube.

1. Steering cable must be the correct length, particularly when installed in larger boats.
2. Avoid sharp bends, kinks or loops in cable.
3. Power Steering Models: Fully extended steering cable end dimension must be correct.
Steering Cable Specifications
c
a
b d
e g
f C
L

j
k h
l
i 21435

a - Coupler Nut - 7/8 - 14 UNF - 2B Thread

b - 11-3/4 in. (298 mm) Min.
c - Interface Point
d - 1/2 in. (12.7 mm) Max.
e - .420 in. (10.668 mm) Min. Flat
f - .102 in. (0.508 mm) Min. Radius
g - 5/8 in. (15.875 mm) Max. Diameter End Fitting
h - 3/8 in. (9.525 mm)
i - .385 in. (9.779 mm) Diameter Through Hole, Chamfered Each Side
j - 1-3/8 in. (34.925 mm) Max.
k - 5/8 in. (15.875 mm) Diameter Tube
l - Mid-Travel Position - 16-7/8 in. (428.6 mm). Total Travel To Be 8 in. (203.2 mm)
Min., to 9 in. (228.6 mm) Max. Travel Each Side of Mid-Travel Position - 4 in.
(101.6 mm) Min., 4-1/2 in. (114.3 mm) Max.

b
a

a - Steering Cable Mounting Flange

b - Center of Hole in Steering Cable End
c - 21-3/8 in. (543 mm) Maximum

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POWER STEERING SERVICE MANUAL NUMBER 14

Filling and Air Bleeding Power Steering System

IMPORTANT: Power Steering system MUST BE filled exactly as explained, following,

to be sure that all air is bled from the system. All air must be removed, or fluid in pump
may foam during operation and be discharged from pump reservoir. Foamy fluid also
may cause Power Steering system to become spongy, which may result in poor boat
control.

1. Position drive unit straight back. Remove fill cap from power steering pump and check
fluid level with dipstick.
2. Add Quicksilver Power Trim and Steering Fluid or Dexron II, as required, to bring fluid
up to correct level.

a a

22023

Engine Warm from Operation Engine Cold

a - Recommended Fluid Level
3. (With engine not running), turn the steering wheel at a moderate rate, back-and-forth,
to end of travel in each direction, pausing each time at end of travel for a few seconds
to allow any air to bubble from pump reservoir. Do this a minimum of 5 complete cycles.
Recheck fluid level and add if necessary.
4. Reinstall fill cap.

CAUTION
DO NOT operate engine without water being supplied to seawater pickup holes in
gear housing. Overheating damage to engine may result.

5. Install flush test device and connect a hose between it and water tap.

22029
NOTE: If using a test tank or if boat is in the water, ensure sterndrive unit gear housing water
intake holes are below water level.

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SERVICE MANUAL NUMBER 14 POWER STEERING

6. Partially open water tap (approximately 1/2 max.) and allow water to enter cooling
system. DO NOT use full water tap pressure.
7. Start engine and run at idle. During this time, turn steering wheel back-and-forth to end
of travel in each direction several times.
8. Position drive unit so that it is straight back and then stop engine. Remove fill cap from
pump. Allow any foam in pump reservoir to disperse, then check fluid level and add fluid,
if needed. DO NOT OVERFILL. Reinstall fill cap and tighten securely.
9. If fluid was foamy in previous step, repeat steps 7 and 8 until fluid does not foam and
level remains constant.

Balancing Power Steering Control Valve

IMPORTANT: Control valve is balanced by the manufacturer and should not require
further adjustment. However, if drive unit tends to creep in one direction or the other
(with engine running, drive unit in neutral, and hands off the steering wheel), the
control valve MUST BE balanced as explained following.

1. Ensure engine is off.

2. Disconnect steering cable from power steering control valve clevis.

b c

d
a

22023
a - Steering Cable
b - Clevis
c - Pin
d - Cotter Pin

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POWER STEERING SERVICE MANUAL NUMBER 14

3. Disconnect power steering control valve clevis from drive unit steering lever.

b c

d
a

22023

a - Clevis
b - Steering Lever
c - Pin
d - Cotter Pin (Hidden)

4. Remove dust cover.

22023
a - Dust Cover

CAUTION
DO NOT operate engine without water being supplied to seawater pickup holes in
gear housing. Water pump damage and overheating damage to engine may result.

WARNING
Remain clear of power steering clevis when starting engine. If control valve is not
balanced, unexpected movement of clevis could cause injury.

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SERVICE MANUAL NUMBER 14 POWER STEERING

5. Connect a flush test device to drive unit. Partially open water tap (approximately 1/2
max.) and allow water to enter cooling system. DO NOT use full water tap pressure.

22029

6. Start engine and adjust control valve by turning adjustment nut as follows:

22023

a - Adjustment Nut

a. If power steering piston rod end clevis moves toward right (starboard), turn nut
clockwise until clevis just begins to move toward left (port), then turn nut
counterclockwise until clevis just begins to move toward right (starboard). Turn nut
clockwise to exactly 1/2 the rotation necessary to change direction of rod end clevis
movement.
b. If power steering piston rod end clevis moves toward left (port), turn nut
counterclockwise until clevis just begins to move toward right (starboard), then turn
nut clockwise until clevis just begins to move toward left (port). Turn nut
counterclockwise to exactly 1/2 the rotation necessary to change direction of rod end
clevis movement.
7. Turn off engine.
8. Apply a liberal amount of Special Lubricant 101 to end of steering cable and install cable
end in clevis. Secure with pin and cotter pin.
9. Torque self-locking coupler nut to 35 lb-ft (48 Nm).

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POWER STEERING SERVICE MANUAL NUMBER 14

10. Install and tighten locking plate on coupler nut. Secure with self-locking bolt and washer
(if required).

d
a

c
50927

a - Clevis Pin
b - Cotter Pin
c - Self-Locking Coupler Nut
d - Steering Cable

11. Reconnect power steering control valve piston rod end clevis to drive unit steering lever.
a

c
b

50927

a - Clevis
b - Steering Lever
c - Pin
d - Cotter Pin

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SERVICE MANUAL NUMBER 14 POWER STEERING

12. Place 2-4-C Marine Lubricant with Teflon in adjustment nut cavity and reinstall dust
cover.

22023

a - Adjustment Nut Cavity

13. Restart engine and observe drive unit. If drive unit still creeps in one direction or the
other, an external tension may exist on steering cable. Ensure that nothing is attached
to steering cable (pushing or pulling).

Steering Cable Selection, Removal and Installation

Selection
Steering system has the steering cable guide tube set for cables with end dimensions which
comply with the BIA Certification Handbook. Refer to “Steering Cable Specifications” listed
previously in this section.

CAUTION
If cables with improper dimensions are installed, severe damage to transom assem-
bly and/or steering system may result.

CAUTION
Steering cables MUST BE THE CORRECT LENGTH, particularly when installed in
large boats. Sharp bends or too-short cables result in kinks; too-long cables require
unnecessary bends and/or loops. Both place an extra stress on the cable. The prop-
er cable is as short as possible, with the fewest bends and with radii as large as pos-
sible.

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POWER STEERING SERVICE MANUAL NUMBER 14

Removal
1. Remove steering cable.
d

c
a

b
50912

a - Steering Cable
b - Self-Locking Cable Coupler Nut
c - Cotter Pin
d - Clevis Pin

Installation
WARNING
Steering cable outer casing MUST BE free to move back-and-forth for steering to
function properly. DO NOT fasten any wires, cables or other items to steering cable,
as this may prevent it from moving.

1. Apply a liberal amount of Special Lubricant 101 to end of steering cable and install cable
end in clevis. Secure with pin and cotter pin.
2. Later model control valve: Using a suitable wrench, hold the flat surfaces on the cable
guide tube in the vertical position.
3. Both models: Torque coupler nut to 35 lb-ft (48 Nm).
4. Earlier model control valve: Install and tighten locking plate on coupler nut. Secure
with self locking bolt and washer.

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SERVICE MANUAL NUMBER 14 POWER STEERING

NOTE: Later model control valves do not have a locking plate on the coupler nut
e

f
b

c
d

50352

Earlier Model Control Valve

a - Clevis Pin
b - Cotter Pin
c - Locking Plate (If No Self Locking Coupler Nut)
d - Coupler Nut
e - Steering Cable
f - Bolt and Washer

b e

c d

f
22217
73901

Later Model Control Valve

a - Clevis Pin
b - Cotter Pin
c - Coupler Nut
d - Steering Cable
e - Flat (Hold Vertical)
f - Suitable Wrench

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POWER STEERING SERVICE MANUAL NUMBER 14

Installation
WARNING
Steering cable outer casing MUST BE free to move back-and-forth for steering to
function properly. DO NOT fasten any wires, cables or other items to steering cable,
as this may prevent it from moving.
1. Apply a liberal amount of Special Lubricant 101 to end of steering cable and install cable
end in clevis. Secure with pin and cotter pin.
2. Later model control valve: Using a suitable wrench, hold the flat surfaces on the cable
guide tube in the vertical position.
3. Both models: Torque coupler nut to 35 lb-ft (48 Nm).
4. Earlier model control valve: Install and tighten locking plate on coupler nut. Secure
with self locking bolt and washer.
NOTE: Later model control valves do not have a locking plate on the coupler nut.
5. Install test gauge assembly between control valve and pump pressure hose. Tighten all
fittings securely, but DO NOT OVERTIGHTEN.

d c

22146

a - Pump Pressure Hose

b - Gauge Fitting
c - Gauge Valve Hose
d - Control Valve

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SERVICE MANUAL NUMBER 14 POWER STEERING

Power Steering Pump Lugging Test

CAUTION
DO NOT operate engine without cooling water being supplied to water pickup holes
in gear housing, or over-heating damage to engine may result.

WARNING
Steering cable outer casing MUST BE free to move back-and-forth for Power
Steering to function properly. Make sure that no wires, cables, or other items are
fastened to steering cable, as this may prevent it from moving.

CAUTION
If Power Steering pump lugs when steering wheel is turned to end of travel in either
direction (left or right), damage to steering system and/or sterndrive may result.

IMPORTANT: Make sure that Power Steering pump is filled to proper level before
proceeding.
1. Completely open test gauge.
2. Start engine and run at idle speed.
3. Turn steering wheel to hard left and observe reading on gauge. If pressure reading is
higher than 300 psi (2069 kPa), stop engine and check the following:
a. Check for an obstruction between gimbal ring and gimbal housing and all moving
steering system components.
b. Check that steering lever is not contacting cutout in transom. If contact is being
made, modify cutout.
c. Check steering cable guide tube dimensions and adjust as necessary.

b a
22137

a - Steering Cable Guide Tube

b - 5/8-7/8 in. (16-22 mm) [Ideal 3/4 in. (19 mm)]

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POWER STEERING SERVICE MANUAL NUMBER 14

4. With engine running, turn steering wheel to hard right and observe reading on gauge.
If reading is higher than 300 psi (2069 kPa), stop engine and check the following.
a. Check for an obstruction between gimbal ring, and gimbal housing and all moving
steering system components.
b. Check that steering lever is not contacting cutout in transom. If contact is being
made, modify cutout.
c. Check steering cable end dimensions with cable fully extended. If excessive,
replace cable and/or steering head as required.

a b

c
22469

a - Steering Cable Mounting Flange

b - Center of Hole in Steering Cable End
c - 21-3/8 in. (543 mm)

d. Check steering cable guide tube dimension and adjust as necessary.

b a
22137

a - Steering Cable Guide Tube

b - 5/8-7/8 in. (16-22 mm) [Ideal 3/4 in. (19 mm)]

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SERVICE MANUAL NUMBER 14 POWER STEERING

Power Steering System Pressure Test

IMPORTANT INFORMATION

The following instructions are arranged so that a defective part can be detected by the
process of elimination. It is suggested that the order of the instructions be followed so that
the Power Steering System can be tested effectively.

1. Remove steering cable from Power Steering unit and disconnect Power Steering unit
from steering lever.
d b a

f
50912

a - Clevis
b - Pins (2)
c - Cotter Pins (2) - Hidden
d - Steering Lever
e - Steering Cable
f - Self-Locking Coupler Nut

2. Assemble and install test gauge.

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POWER STEERING SERVICE MANUAL NUMBER 14

3. Open valve on gauge completely.

d c

22146

a - Pump Pressure Hose

b - Gauge Fitting
c - Gauge Valve Hose
d - Control Valve

4. Connect a flush test device to drive unit. Partially open water tap (approximately 1/2
max.) and allow cooling system to fill completely. Cooling system is full when water is
discharged through the propeller. DO NOT use full water tap pressure.

22029

5. Start engine and run at 1000-1500 rpm until engine reaches normal operating
temperature.
6. With engine at idle speed, test gauge reading should be between 70 and 125 psi (483
and 862 kPa). If not, proceed as follows:
If lower than 70 psi (483 kPa), proceed to “Pump Pressure Test,” see “Index.”
If higher than 125 psi (862 kPa), check for hose restrictions in the system.

CAUTION
DO NOT lug pump at maximum pressure for more than 5 seconds, in next step, or
damage to Power Steering pump may occur.
7. Push control valve adaptor block momentarily to the left and then to the right. Gauge
reading should show an instant increase in pressure when block is pushed in both
directions.

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SERVICE MANUAL NUMBER 14 POWER STEERING

8. Push control valve adaptor block to the right, until booster cylinder piston rod is fully
retracted. With piston rod in this position, momentarily push adaptor block to the right
until maximum pressure reading is obtained.
• If pressure is above 1000 psi (6897 kPa), system pressure is good.
• If pressure is below 1000 psi (6897 kPa), conduct “Pump Pressure Test,” see “Index.”

22023

a - Control Valve Adaptor Block

Pump Pressure Test

CAUTION
In performing the following test, DO NOT lug pump at maximum pressure for more
than 5 seconds or damage to Power Steering pump may occur.
1. Install test gauge.

d c

b
22146

a - Pump Pressure Hose

b - Gauge Fitting
c - Gauge Valve Hose
d - Control Valve

DO NOT operate engine without cooIing water being supplied to water pickup holes in gear
housing, or overheating damage to engine may result.

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POWER STEERING SERVICE MANUAL NUMBER 14

2. Connect a flush test device to drive unit. Partially open water tap (approximately 1/2
max.) and allow water to enter cooling system. DO NOT use full water tap pressure.

22029

3. Start engine and run at 1000-1500 rpm until engine reaches normal operating
temperature.
4. Close test gauge valve just long enough to obtain maximum pressure reading.

5. Close and open valve 3 times. Record highest pressure reading attained each time.
a. If pressure readings are between 1150 and 1250 psi (7932-8621 kPa) and are
within a range of 50 psi (345 kPa), the pump is within specifications. If the pump
tests OK, but system pressure was low (as tested under “Power Steering System
Pressure Test,” see “Index”), proceed to “Booster Cylinder Test,” see “Index.”
b. If pressure readings are between 1150-1250 psi (7932-8621 kPa), but are not
within a 50 psi (345 kPa) range, the Power Steering pump flow control valve is
sticking or pump hydraulic system is dirty.
c. If pressure readings are constant, but below 1000 psi (6897 kPa), replace Power
Steering pump.

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SERVICE MANUAL NUMBER 14 POWER STEERING

Booster Cylinder Test

CAUTION
DO NOT operate engine without cooling water being supplied to water pickup holes
in gear housing, or over-heating damage to engine may result.
1. Connect a flush test device to drive unit. Partially open water tap (approximately 1/2
max.) and allow water to enter cooling system. DO NOT use full water tap pressure.

22029

2. Start engine.
3. Push control valve adaptor block to the right until booster cylinder rod is fully retracted.
4. Stop engine.
5. Remove top metal hydraulic line from control valve.
6. Plug port in control valve and cap end of metal line with cap and plug supplied in test
gauge kit.

a
b

22023
a - Adaptor Block - Push To Right
b - Top Metal Line

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POWER STEERING SERVICE MANUAL NUMBER 14

CAUTION
DO NOT lug pump at maximum pressure for more than 5 seconds, in next step, or
damage to Power Steering pump may occur.

7. Start engine.
8. Push control valve adaptor block momentarily to the right and observe for conditions
“a” or “b,” following:
a. If piston rod extends, booster cylinder is leaking and must be replaced. After
replacement, repeat “Power Steering System Pressure Test.” If pressure is still low,
replace control valve.
b. If piston rod does not extend, but pressure was low when performing “Power
Steering System Pressure Test,” replace control valve.
9. Stop engine.
10. Connect power steering piston rod clevis to drive unit steering lever. Secure with pin and
cotter pin.
11. Apply a liberal amount of Special Lubricant 101 to end of steering cable and install cable
end in clevis. Secure with pin and cotter pin.
12. Torque self-locking coupler nut to 35 lb-ft (48 Nm).
d a

e
b

f
50927

a - Clevis
b - Pins (2)
c - Cotter Pins (2)
d - Steering Lever
e - Steering Cable
f - Self-Locking Coupler Nut

Page 6A-28 90-818177--3 APRIL 2001

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SERVICE MANUAL NUMBER 14 POWER STEERING

Power Steering Component Repair

NOTE: DO NOT attempt to repair or adjust the later model control valve.

22217

Later Model Control Valve

a - Later Model Control Valve (Do Not Repair or Adjust)

Power Steering Unit

REMOVAL
1. Remove steering cable and Power Steering pump fluid hoses.
b

a c
e

d 50912 50912

a - Cotter Pin (Hidden)

b - Clevis Pin
c - Power Steering Pump Fluid Hoses - Remove and Plug
d - Self-Locking Cable Coupler Nut
e - Steering Cable

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INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

2. Remove Power Steering unit.

b c

a b c 22137
a - Power Steering Unit
b - Tab Washer - Bend Tab Away from Pivot Bolt
c - Pivot Bolt

INSTALLATION
1. Lubricate power steering unit bushings with Special Lubricant 101..

22167

a - Bushings

2. Lubricate pivot bolts with Special Lubricant 101.

3. HAND THREAD pivot bolts all-the-way into inner transom plate and swivel ring. DO NOT
use a wrench.
4. Straddle tab washer tangs on inner transom plate ridge.

c b
c
a

a b

22168

a - Pivot Bolts - HAND THREAD into Transom Plate and Power Steering Unit
b - Tab Washer - Straddle Inner Transom Plate Ridge
c - Swivel Ring

5. Torque pivot bolts to 25 lb-ft (35 Nm). Bend washer tabs against corresponding flats on
bolt tabs.

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SERVICE MANUAL NUMBER 14 POWER STEERING

6. Move power steering unit back-and-forth to ensure that it pivots freely.

22169
a - Move Power Steering Unit Back-and-Forth

7. Connect power steering piston rod clevis to drive unit steering lever. Secure with pin and
cotter pin.
a

d b

c
50927

a - Clevis
b - Pin
c - Cotter Pin
d - Steering Lever

8. Apply a liberal amount of Special Lubricant 101 to end of steering cable and install cable
end in clevis. Secure with pin and cotter pin.

90-818177--3 APRIL 2001 Page 6A-31

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

9. Torque self-locking coupler nut to 35 lb-ft (48 Nm).

d
a

50927
a - Clevis Pin
b - Cotter Pin
c - Self-Locking Coupler Nut
d - Steering Cable

10. Connect power steering pump hoses to their respective fittings on control valve. Torque
large hose fitting to 20-25 lb-ft (27-34 Nm). Torque the small hose fitting to 96-108 lb-in.
(11-12 Nm).

50912

a - Hose (Large Fitting)

b - Hose (Small Fitting)

Page 6A-32 90-818177--3 APRIL 2001

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SERVICE MANUAL NUMBER 14 POWER STEERING

Cable Guide Tube (Early Style Only)

REMOVAL
1. Remove power steering pump hoses from control valve. Cap hoses and plug holes in
control valve.

a b

50912
a - Control Valve
b - Pump Hoses

2. Remove steering cable from power steering control valve.

a

50912

a - Clevis Pin
b - Cotter Pin (Hidden)
c - Self-Locking Coupler Nut
d - Steering Cable

90-818177--3 APRIL 2001 Page 6A-33

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

3. Remove adaptor block as follows:

a. Loosen adaptor block nut.
b. Tap adaptor nut with hammer to loosen block.
c. Remove nut; then remove block.

b
a

22137

a - Adaptor Block
b - Nut

4. Heat area shown (to break down Loctite), and remove steering tube bushing, guide, and
nut. Remove cable guide tube.

b
c
d e 22137
a - Heat in This Area
b - Steering Tube Bushing
c - Steering Tube Guide
d - Steering Tube Nut
e - Cable Guide Tube

Page 6A-34 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

INSTALLATION

WARNING
Loctite MUST BE applied to cable guide tube threads to prevent tube from
loosening during operation.

1. Clean guide tube threads with a wire brush to remove old Loctite. Apply Quicksilver
Loctite 8831 or 271 to guide tube threads in the area where adaptor block and locknut
will be installed.

a 22137

a - Loctite 8831 or 271 to Threads of Cable Guide Tube

2. Reinstall steering tube and related hardware and position so that threaded end of tube
protrudes exactly 3/4 in. (19 mm) through adaptor block. Torque steering tube nut to 40
lb-ft (54 Nm).

c d a
b

e
22137

a - Steering Guide Tube

b - Steering Tube Bushing
c - Steering Tube Guide
d - Steering Tube Nut
e - 3/4 in. (19 mm)

3. Apply a liberal amount of Special Lubricant 101 to end of steering cable and install cable
end in clevis. Secure with pin and cotter pin.

90-818177--3 APRIL 2001 Page 6A-35

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

4. Torque self-locking coupler nut to 35 lb-ft (48 Nm).

d
a

c
50927

a - Clevis Pin
b - Cotter Pin
c - Self-Locking Coupler Nut
d - Steering Cable

5. Connect power steering pump hoses to their respective fittings on control valve.

50912

a - Hose (Large Fitting) - Torque to 20-25 lb-ft (27-34 Nm)

b - Hose (Small Fitting) - Torque to 96-108 lb-in. (11-12 Nm)

Page 6A-36 90-818177--3 APRIL 2001

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SERVICE MANUAL NUMBER 14 POWER STEERING

Control Valve (Early Style Only)

NOTE: If accessibility to control valve area is limited, remove Power Steering unit from tran-
som assembly, to gain easier access to control valve.

REMOVAL
1. Remove steering cable and Power Steering pump fluid hoses.

d 50912

a - Cotter Pins (Hidden)

b - Clevis Pins
c - Power Steering Pump Fluid Hoses - Remove and Plug
d - Cable Self-Locking Coupler Nut
e - Steering Cable

2. Remove tubes from control valve.

a - Metal Tubes

90-818177--3 APRIL 2001 Page 6A-37

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

3. Heat area shown (to breakdown Loctite), and remove steering tube bushing, guide and
nut.

b
c
d e 22137

a - Heat this Area

b - Steering Tube Bushing
c - Steering Tube Guide
d - Steering Tube Nut
e - Cable Guide Tube

4. Remove control valve from adaptor block assembly.

d c
a b 22143

a - Control Valve
b - Adaptor Block Assembly
c - Screw
d - Washer

Page 6A-38 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

DISASSEMBLY

1. Remove adaptor block as follows:

Loosen adaptor block nut. Tap adaptor nut with hammer to loosen block. Remove nut,
washer and adaptor block.

b
a

c
d 22143

a - Adaptor Block Nut

b - Washer
c - Adaptor Block
d - Control Valve

2. Remove dust cover and adjusting nut.

a b

22139

a - Dust Cover
b - Adjusting Nut

3. Separate valve housing from adaptor.

b d 22145

a - Valve Housing
b - Adaptor
c - Screws (2)
d - Lockwashers (2)

90-818177--3 APRIL 2001 Page 6A-39

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

4. Remove components shown.

n m
l p
d k h
a
j
g f
e
c i
b
o
22138

a - Valve Spool
b - Valve Adjustment Spring
c - Reaction Spool
d - Spring Thrust Washer
e - Valve Spring
f - Spring Retainer
g - Annulus Seal
h - Large ID Washer
i - Reaction Spool O-ring
j - Valve Spool “V” Block Seal
k - Annulus Spacer
l - Gasket
m - Small Washer
n - Plug to Sleeve Key
o - O-ring
p - Valve Housing

5. Carefully (so as not to nick the top surface) turn adjuster plug out of sleeve.

a b
22139

a - Adjuster Plug
b - Turn Counterclockwise

Page 6A-40 90-818177--3 APRIL 2001

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SERVICE MANUAL NUMBER 14 POWER STEERING

6. Remove components shown.

c b 22139

a - Valve Shaft
b - Ball Seal Spring
c - Upper Ball Seat

7. Remove sleeve bearing and lower ball seat.

b c

22140

a - Ball Stud - Pull Up into Rubber Boot

b - Sleeve Bearing
c - Lower Ball Seat

8. Clean and inspect metal parts. If any metal part shows signs of wear, replace control
valve assembly.

90-818177--3 APRIL 2001 Page 6A-41

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

REASSEMBLY
1. Install lower ball seat into sleeve bearing.

b
a 22140

a - Lower Ball Seat

b - Sleeve Bearing

2. Install sleeve bearing.

c b
a 22140

a - Sleeve Bearing
b - Ball Stud - Pull Up into Rubber Boot
c - Adaptor Housing

3. Position ball stud in sleeve bearing.

4. Install upper ball seat.

22141

a - Upper Ball Seat

Page 6A-42 90-818177--3 APRIL 2001

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SERVICE MANUAL NUMBER 14 POWER STEERING

5. Install ball seat spring.

a
22141

a - Ball Seat Spring - Small Coil Down

6. Insert valve shaft into adjuster plug. Screw adjuster plug into sleeve until tight; then
back-off plug until slot lines up with notches in sleeve.

a
b
22139

a - Valve Shaft
b - Adjuster Plug

7. Install key.

22141

a - Key - Tangs on Key to Fit into Notches in Sleeve

90-818177--3 APRIL 2001 Page 6A-43

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

8. Install components shown.

a d
b c 22141

a - Valve Shaft Washer

b - Gasket
c - Annulus Spacer
d - Large ID Washer

9. Install O-ring in control valve housing.

a 22142

a - O-ring
b - Control Valve Housing

10. Install “V” block seal. Insert valve spool into adjusting nut end of control valve.

b a
c 22142

a - “V” Block Seal - Lip of Seal Facing Lands on Spool

b - Spool
c - Control Valve

Page 6A-44 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

11. Assemble reaction spool.

f e d a
c

22142
a - Reaction Spool
b - O-ring
c - Thrust Washer
d - Valve Spring
e - Spring Retainer
f - Annulus Seal - Lip Facing O-ring End of Spool

12. Install valve adjustment spring.

a b

22142

a - Valve Adjustment Spring

b - Control Valve

13. Install reaction spool assembly into larger control valve cavity.

a 22142

a - Reaction Spool Assembly

b - Control Valve - Large Cavity

90-818177--3 APRIL 2001 Page 6A-45

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

14. Install large ID washer.

b a

22144

a - Large ID Washer
b - Valve Shaft

15. Match annulus spacer to control valve housing. Secure adaptor housing to control valve
housing.

c
a 22144

a - Annulus Spacer
b - Control Valve Housing
c - Adaptor Housing
d - Screws and Washers (2 Each) - Torque Screws to 20-30 lb-ft (27-41 Nm)

16. Depress valve spool. Install locknut-thread about 4 turns.

c a 22139

a - Valve Spool
b - Valve Shaft
c - Locknut

Page 6A-46 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

17. Install dust cover.

a 22143

a - Dust Cover

18. Lubricate control valve with Quicksilver 2-4-C Marine Lubricant with Teflon until lubricant
appears around rubber boot.

b 22143

a - Grease Fitting
b - Rubber Boot

19. Install adaptor block.

b
c

22143

a - Adaptor Block
b - Internal Lockwasher
c - Nut - Torque to 30-40 lb-ft (41-54 Nm)

90-818177--3 APRIL 2001 Page 6A-47

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

INSTALLATION
1. Secure control valve to adaptor block assembly. Torque to 25-35 lb-ft (34-47 Nm).

c d
a b 22143

a - Control Valve
b - Adaptor Block Assembly
c - Washer
d - Screw-

2. Install metal tubes onto control valve.

b
22137
a - Metal Tubes
b - Control Valve

WARNING
Loctite MUST BE applied to cable guide tube threads to prevent tube from
loosening during operation.

3. Clean guide tube threads with a wire brush to remove old Loctite. Apply a liberal amount
of Loctite 8831 or 271 to guide tube threads in the area where adaptor block and locknut
will be installed.

a 22137

a - Loctite 8831 or 271 to Threads of Cable Guide Tube

Page 6A-48 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

4. Reinstall steering tube and related hardware and position so that threaded end of tube
protrudes exactly 3/4 in. (19 mm) through adaptor block. Torque steering tube nut to 40
lb-ft (54 Nm).

b c d a

e
22137

a - Steering Guide Tube

b - Steering Tube Bushing
c - Steering Tube Guide
d - Steering Tube Nut
e - 3/4 in. (19 mm)

5. Apply a liberal amount of Special Lubricant 101 to end of steering cable and install cable
end in clevis. Secure with pin and cotter pin.
6. Torque self-locking coupler nut to 35 lb-ft (48 Nm).

d
a

50927

a - Clevis Pin
b - Cotter Pin
c - Self-Locking Coupler Nut
d - Steering Cable

7. Connect power steering pump hoses to the respective fittings on control valve.

8. Torque large hose fitting to 23 lb-ft ( 30.5 Nm).

90-818177--3 APRIL 2001 Page 6A-49
INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

9. Torque the small hose fitting to 102 lb-in. (11.5 Nm).

b
50912

a - Hose (Large Fitting)

b - Hose (Small Fitting)

Booster Cylinder (Early Style Only)

REMOVAL
NOTE: If accessibility to booster cylinder area is limited, remove Power Steering unit from
transom assembly to gain easier access to booster cylinder.

1. Remove steering cable and Power Steering pump fluid hoses.

e b

a
c

d 50912 50912

a - Cotter Pin (Hidden)

b - Clevis Pin
c - Power Steering Pump Fluid Hoses - Remove and Plug
d - Self-Locking Cable Coupler Nut
e - Steering Cable

2. Remove metal lines from control valve.

22137

a - Metal Lines

Page 6A-50 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

3. Remove control valve from adaptor block assembly.

d c
a b 22143

a - Control Valve
b - Adaptor Block Assembly
c - Screw
d - Washer

4. Remove clevis assembly.

b
a c

d
22157

a - Clevis Assembly
b - Nut
c - Washer
d - Booster Cylinder

5. Separate booster cylinder from adaptor block assembly.

b
d

a
b
c
22158
a - Cotter Pin
b - Retaining Pins (2)
c - Booster Cylinder
d - Adaptor Block Assembly

90-818177--3 APRIL 2001 Page 6A-51

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

6. Remove lines from booster cylinder.

22157

a - Metal Lines

7. Remove components shown.

b a
c

22149

a - Snap Ring
b - Large Oil Seal
c - Small Oil Seal

INSTALLATION

1. Install components shown.

b c

a 22149

a - Small Oil Seal - Lip In

b - Large Oil Seal - Lip Out
c - Snap Ring - Install In Groove

2. Install metal lines. Tighten Securely, BUT DO NOT OVERTIGHTEN

22157

a - Metal Lines

Page 6A-52 90-818177--3 APRIL 2001

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SERVICE MANUAL NUMBER 14 POWER STEERING

3. Install adaptor block assembly.

b c a d 22158

a - Adaptor Block Assembly

b - Booster Cylinder
c - Retaining Pins
d - Cotter Pin - Spread Both Ends

4. Install clevis assembly.

a b c

22157

a - Clevis Assembly
b - Washer
c - Nut - Tighten Securely

5. Secure control valve to adaptor block assembly. Torque to 30 lb-ft (40.5 Nm)

c d
a
b 22143

a - Control Valve
b - Adaptor Block Assembly
c - Washer
d - Screw

6. Install metal lines onto control valve. Tighten Securely BUT DO NOT OVER-TIGHTEN

b 22137

a - Metal Lines
b - Control Valve

90-818177--3 APRIL 2001 Page 6A-53

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

7. Apply a liberal amount of Special Lubricant 101 to end of steering cable and install cable
end in clevis. Secure with pin and cotter pin.
8. Torque self-locking coupler nut to 35 lb-ft (48 Nm).

c
50927

a - Clevis Pin
b - Cotter Pin
c - Self-Locking Coupler Nut
d - Steering Cable

9. Connect power steering pump hoses to their respective fittings on control valve.

10. Torque large hose fitting to 23 lb-ft ( 30.5 Nm).

11. Torque the small hose fitting to 102 lb-in. (11.5 Nm).

b
50912

a - Hose (Large Fitting)

b - Hose (Small Fitting)

Page 6A-54 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

Power Steering Pump

Removal
1. Disconnect hoses at pump. Cap hose and fittings.
2. Loosen pump bolts at engine to remove pump belt.
3. Remove bracket from pump.
Flow Control Valve Servicing
1. Drain fluid from pump.
2. Remove components shown.

a
b
c

d
22149

a - Fitting Assembly
b - Control Valve Assembly
c - Flow Control Spring
d - O-rings

3. Inspect control valve assembly and fitting assembly.

4. Install components shown.
5. Torque to 35 lb-ft (47 Nm).

d
c b
a

c
22149

a - Flow Control Spring

b - Control Valve Assembly
c - New O-rings
d - Fitting Assembly

90-818177--3 APRIL 2001 Page 6A-55

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

Pump Shaft Oil Seal Replacement

1. Remove pump pulley.

22149

a - Kent Moore Pulley Removal Tool (J-25034)

2. Push a .005 in. (0.13 mm) shim stock past oil seal until it bottoms in pump body
(approximately 2-1/2 in. [64 mm] long).
3. Cut seal and tear metal body approximately 1 in. (25 mm).

b
a

22152

a - Oil Seal
b - Chisel - To Cut Seal
c - Shim Stock

4. Remove oil seal. Remove shim stock.

22152

a - Torn Seal
b - Awl

Page 6A-56 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

5. Install new oil seal.

NOTE: Properly Support so Reservoir Back Does Not Distort

c 22151

a - New Oil Seal - Metal Side Up

b - 1 in. Socket
c - Pump Reservoir

6. Install pulley, as follows, using Pulley Pusher Assembly 91-93656A1, and a long straight
edge:
a. Place pulley on pump shaft.
b. Thread stud ALL-THE-WAY into pump shaft. Place bearing over stud. DO NOT use
spacer from kit.
c. Thread nut onto shaft. Thread shaft (and nut) ALL-THE-WAY onto stud.
d. Using a long straight edge (to check drive belt alignment), turn large pusher nut until
drive belt is parallel to straight edge.

90-818177--3 APRIL 2001 Page 6A-57

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

e. Check pulley installation for correct alignment.

b c d e f

a - Power Steering Pump Pulley

b - Stud
c - DO NOT Use Spacer
d - Bearing
e - Nut
f - Shaft
g - Crankshaft Pulley (Shown) or Water Circulating Pump Pulley
h - Long Straight Edge
i - Drive Belt Parallel

Disassembly
1. Drain fluid from pump.
2. Remove pump pulley.

22149
a - Kent Moore Pulley Removal Tool (J-25034)

Page 6A-58 90-818177--3 APRIL 2001

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SERVICE MANUAL NUMBER 14 POWER STEERING

3. Remove reservoir.

d f f

a b c f e
f 22155

a - Fitting Assembly
b - Control Valve Assembly
c - Flow Control Spring
d - Studs
e - Reservoir
f - O-rings

4. Remove retaining ring and end plate.

b 22150

a - Retaining Ring - Position so that Ring End is 1 in. (25 mm) from End of Hole in
Housing
b - Hole
c - Screwdriver

90-818177--3 APRIL 2001 Page 6A-59

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

5. Remove pump components shown.

b c d e
a f

f
22155

a - Spring
b - Pressure Plate
c - Pump Ring
d - Pump Vanes
e - Pump Shaft and Rotor Assembly
f - Dowel Pins

6. Remove and discard O-rings from housing.

a
22155

a - O-rings - Discard

7. Remove rotor and thrust plate.

a c d
b 22155

a - Retaining Ring
b - Rotor
c - Thrust Plate
d - Pump Shaft

8. Remove magnet.

a
22154

a - Magnet

Page 6A-60 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

Cleaning And Inspection

1. Clean and inspect all metal parts.
Reassembly
NOTE: All references to Power Steering fluid refer to Quicksilver Power Trim and Steering
Fluid, or Dexron II if Quicksilver product is not available.
NOTE: Obtain and install a new seal kit 5688044 from a local GM automotive dealer when
reassembling pump.
1. Install new pump shaft oil seal.
NOTE: Properly support so the back of the reservoir does not distort.

22151

a - New Oil Seal - Metal Side Up

b - 1 in. Socket
c - Pump Reservoir

2. Install pressure plate O-ring and dowel pins.

a c

22150

a - Pressure Plate O-ring - Lubricate with Power Steering Fluid; Place in Third
Groove in Housing
b - Dowel Pins

90-818177--3 APRIL 2001 Page 6A-61

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

3. Assemble pump shaft and rotor assembly.

d a
c b 22155

a - Pump Shaft
b - Thrust Plate
c - Rotor - Countersunk Side Toward Thrust Plate
d - Retaining Ring

4. Install pump shaft and rotor assembly.

a
22154

a - Pump Shaft and Rotor Assembly

b - Pump Housing

5. Install pump ring.

a 22154

a - Pump Ring - Place 2 Smaller Holes Over Dowel Pins

Page 6A-62 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

6. Install vanes in rotor slots - Rounded edges toward pump ring. Vanes must slide freely.

22154

a - Vanes - Rounded Edges Toward Pump Ring

7. Install pressure plate.

a
22154

a - Pressure Plate
b - Spring Groove - Facing Up

8. Install end plate O-ring.

22150

a - End Plate O-ring - Lubricate with Power Steering Fluid; Place in Second
Groove in Housing

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INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

9. Install pressure plate spring, end plate and retaining ring.

22151

a - Pressure Plate Spring

b - End Plate

22152

a - Retaining Ring
b - Arbor Press -

10. Install reservoir O-rings.

a

22153

a - Reservoir O-ring - Lubricate with Power Steering Fluid; Install in Groove in

Pump Housing

Page 6A-64 90-818177--3 APRIL 2001

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SERVICE MANUAL NUMBER 14 POWER STEERING

11. Place magnet on housing.

22153

a - Magnet

12. Secure reservoir to pump housing. Torque studs to 35 lb-ft (47 Nm).

22153

a - Reservoir
b - Pump Housing
c - Studs

13. Install components shown. Torque fitting assembly to 35 lb-ft (47 Nm).

d b
a

22153

a - Flow Control Spring

b - Control Valve Assembly
c - O-ring - for Fitting Assembly
d - Fitting Assembly

90-818177--3 APRIL 2001 Page 6A-65

INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

14. Install pulley, as follows, using Pulley Pusher Assembly 91-93656A1, and a long straight
edge:
a. Place pulley on pump shaft.
b. Thread stud ALL-THE-WAY into pump shaft. Place bearing over stud. DO NOT use
spacer from kit.
c. Thread nut onto shaft. Thread shaft (and nut) ALL-THE-WAY onto stud.
d. Using a long straight edge (to check drive belt alignment), turn large pusher nut until
drive belt is parallel to straight edge.
e. Check pulley installation for correct alignment.

c d e f
b

a - Power Steering Pump Pulley

b - Stud
c - DO NOT Use Spacer
d - Bearing
e - Nut
f - Shaft
g - Crankshaft Pulley (Shown) or Water Circulating Pump Pulley
h - Long Straight Edge
i - Drive Belt Parallel

15. Install power steering pump on engine. (Refer to appropriate Engine Service Manual.)

Page 6A-66 90-818177--3 APRIL 2001

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SERVICE MANUAL NUMBER 14 POWER STEERING

Multiple Sterndrive Steering Tie Bar Arrangements

With multiple sterndrives it is important to consider which of several possible steering sys-
tems should be selected.

CAUTION
Failure to observe the recommended Tie Bar Arrangements as presented in this
section could result in serious damage to the steering and/or trim system compo-
nents. This damage could adversely affect control of the boat.
INTERNAL TIE BAR ONLY
At the lower end of the performance spectrum (boats not capable of speeds in excess of
60 MPH) the basic internal tie bar is recommended. It connects the slave sterndrive to the
sterndrive that is directly connected to the factory power steering output. This internal tie
bar is available in a variety of lengths from the sterndrive manufacturer.

INTERNAL AND EXTERNAL TIE BAR

As a boat moves into a moderate performance range (60-70 MPH) or for a reduction in steer-
ing backlash, an external tie bar should be added. External tie bars are usually designed
to attach at the aft power trim cylinder bosses which is an excellent location because of its
proximity to the propeller. HOWEVER, because of the potential overstress that can occur
if one drive is trimmed much differently than the other, a dual trim control kit (Part Number
90362A3) should be installed so as to limit this potential tilt differential to about 20°.

EXTERNAL POWER STEERING

When boat speeds move past 70 MPH or if additional steering backlash reduction is desired,
external power steering is recommended. This normally will include an external tie bar
mounted at the same general location of the power steering cylinders which are generally
attached at the top of the sterndrive’s drive shaft housing. With this steering system, no inter-
nal tie bar should be used. These steering cylinders can be attached either inboard (be-
tween) or outboard of the sterndrives.

EXTERNAL POWER STEERING WITH LOW EXTERNAL TIE BAR

For the fastest boats (over 80 MPH) or for the ultimate in steering backlash reduction, use
external power steering, BUT (where mechanically possible) with the external tie bar
mounted at the trim cylinder boss location (as previously described in “Internal and External
Tie Bar” statements). Again this system does not use an internal tie bar.
Mercury Marine does not recommend the use of an external tie bar ONLY (no internal tie
bar) when using the internal power steering system. This can cause excessive loads on the
steering components on the drive connected to the internal power steering system. These
increased loads can damage the steering components, resulting in increased play in the
steering of the boat.
Determining Tie Bar Length
WARNING
ON DUAL INSTALLATION USING STARBOARD TIE BAR KIT. The steering cable
MUST have a minimum radius of 8 in. (203 mm) at the transom end. A radius less
than 8 in. (203 mm) may kink the steering cable which, in turn, may affect steering
operation. If the minimum 8 in. (203 mm) requirement cannot be met due to boat
construction, etc., steering cable must then be routed to port transom and a port
transom and a port tie bar kit 96708A4, A5 or A6 MUST BE used in place of the
starboard tie bar kit.

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POWER STEERING SERVICE MANUAL NUMBER 14

NOTE: If drive units are to be “toed-in” or “toed-out,” measure from centerlines of steering
levers (with drive units positioned as desired), instead of centerlines of power packages. In
most cases, the best boat handling and performance characteristics will be obtained with
the drive units positioned parallel.
1. Determine tie bar length.
a. Measure centerline distance (Dimple in Gimbal Housing is located beneath the
decal in the top center).
b. Apply measurement to appropriate chart to determine tie bar length.

b c

70133

a - Distance Between Centerlines

b - Port Transom Assembly Centerline
c - Starboard Transom Assembly Centerline

Selection

TIE BAR CHART

For Dual Installations with Steering Cable Attached to Starboard Power Package
* 16” to 30” 92020A1
* 30” to 46” 92020A2
46” to 62” 92020A3
* If centerline distance is the same as maximum figure, use next larger size tie bar.

TIE BAR CHART

For Dual Installations with Steering Cable Attached to Port Power Package
* 28” to 37-1/2” 96708A4
* 37-1/2” to 55” 96708A5
55” to 72” 96708A6
* If centerline distance is the same as maximum figure, use next larger size tie bar.

Page 6A-68 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

Installation
DUAL INSTALLATIONS WITH STEERING CABLE ATTACHED TO STARBOARD POWER PACKAGE
1. Install tie bar.
a. Attach fixed bar end to steering lever, using clevis pin and cotter pin. Spread cotter
pin ends.

b
c

a
22079
d

22211

a - Fixed End
b - Steering Lever
c - Clevis Pin
d - Cotter Pin

b. Position drive units as desired and turn adjustable end (if necessary) to align hole
in bar with holes in steering lever and piston rod end clevis.
c. Turn adjustable end out 3 to 4 turns from aligned position. Apply Loctite 8831 or
equivalent, to exposed tie bar threads; then turn tie bar back in to previously aligned
position.
d. Attach tie bar end using clevis pin and cotter pin. Spread cotter pin ends.

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INDEX
POWER STEERING SERVICE MANUAL NUMBER 14

e. Apply Loctite 8831 or equivalent, to exposed tie bar threads. Torque locknut to 40-60
lb-ft (54-81 Nm).

e 22079
g f

22211

e - Adjustable End
f - Clevis Pin
g - Cotter Pin
h - Locknut

DUAL INSTALLATIONS WITH STEERING CABLE ATTACHED TO PORT POWER PACKAGE

1. Install tie bar.
a. Attach fixed bar end to steering lever, using clevis pin and cotter pin. Spread cotter
pin ends.

b c

22211
22079

a - Fixed Bar End

b - Steering Lever
c - Clevis Pin
d - Cotter Pin

b. Position drive units as desired and turn adjustable end (if necessary) to align hole
in bar with holes in steering lever and piston rod end clevis.

Page 6A-70 90-818177--3 APRIL 2001

INDEX
SERVICE MANUAL NUMBER 14 POWER STEERING

c. Turn adjustable end out 3 to 4 turns from aligned position. Apply Loctite 8831 or
equivalent, to exposed tie bar threads; then turn tie bar back in to previously aligned
position.
d. Attach tie bar end using clevis pin and cotter pin. Spread cotter pin ends.
e. Apply Loctite 8831 or equivalent, to exposed tie bar threads. Torque locknut to 40-60
lb-ft (54-81 Nm).

f g
22079

22211

e - Adjustable End
f - Clevis Pin
g - Cotter Pin
h - Locknut

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POWER STEERING SERVICE MANUAL NUMBER 14

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Page 6A-72 90-818177--3 APRIL 2001