How to adjust the steering relief plungers and axle stops on your vehicle

Part 1: Important Safety Precautions 
WARNING: Safety is the personal responsibility of the technician. Failure to follow proper safety 
procedures can result in serious injury or death. 

• Personal Protective Equipment (PPE): Always wear appropriate safety gear, including safety glasses and gloves. 
• Secure the Vehicle: Before working under or near the vehicle, ensure it is on a solid, level surface. Always use wheel chocks to prevent the vehicle from rolling. 
• Use Safety Stands: Never work under a vehicle supported only by a jack. Always use certified safety stands (jack stands) to support the front axle once it is lifted. 
• Use a Helper: This procedure requires a second person in the cab to turn the steering wheel while adjustments are made. Clear communication is essential. 
• Beware of Pinch Points: Always be aware of your surroundings. The steering linkage, wheels, and suspension components create numerous pinch points that can cause severe injury. Keep hands and tools clear of moving parts. 

Tools Required:

• Hydraulic Jack 
• Certified Safety Stands 
• Wheel Chocks 
• Wrenches to fit axle stop bolts and lock nuts. 
• Long, straight screwdriver for right-turn plunger 
• Tool for left-turn plunger (square stock may be required) 

Part 2: Preparation and Axle Stop Removal 

1. Park Safely: Park the vehicle on a clean, dry, and solid surface. Concrete is preferable. 
2. Secure Vehicle:
   1. Set the parking brake firmly. 
   2. Chock the wheels that will remain on the ground to prevent rolling. 
3. Lift Front Axle: Use a hydraulic jack to raise the front of the vehicle until both front tires are completely off the ground. Place safety stands securely under the axle.
4. Remove Axle Stops: Locate the adjustable axle stop bolts seen in figure 1 on each spindle. Loosen the lock nuts and completely remove both the left and right axle stop bolts. Set them aside for reinstallation later. 

Figure 1: Adjustable Axle Stop Bolt

Part 3: Setting Maximum Wheel Cut with Relief Plungers 
IMPORTANT: The full weight of the vehicle must be on the ground for this part of the adjustment. 

1. 1. Lower Vehicle: Carefully lower the front of the vehicle so its full weight is back on the tires. Remove the jack and safety stands. 
2. Start Engine: Turn on the vehicle to operate the power steering system. 
3. Adjust for Full Right Turn:
   
   1. With the wheels pointed straight ahead, have a helper in the cab. 
   2. Locate the right-turn relief plunger adjustment screw seen in figure 2 on the steering gear. 
   3. WARNING: While adjusting, ensure the tire does not make contact with the vehicle Adjust for Full Right Turn: frame, drag link, or any other chassis component. Maintain a safe clearance at all times. 
   4. Have the helper turn the steering wheel to the right. Adjust the plunger OUT (counterclockwise) with a long screwdriver to increase the wheel cut until the steering wheel stops at 2.5 revolutions from the center position. 
4. Adjust for Full Left Turn:
   1. Repeat step 3 using the left-turn relief plunger adjustment screw and turning the steering wheel left instead of right.

Figure 2:Relief Plunger Adjustment Screw

 

Figure: Plunger Adjustment

Part 4: Reinstall Axle Stops and Final Checks 

1. Lift Front Axle Again: Raise the front of the vehicle with the jack until the tires are clear of the surface and place safety stands under the axle. 
2. Reinstall and Set Axle Stops:
   1. Turn the steering to the full right turn position, where the relief plunger stops it.
   2. Reinstall the right-side axle stop bolt. Adjust it until there is a 1/8-inch clearance between the stop bolt and the axle.
   3. Tighten the lock nut on the stop bolt securely.
   4. Turn the steering to the full left turn position. Reinstall the left-side axle stop bolt and adjust it for a 1/8-inch clearance.
   5. Tighten the left-side lock nut securely. 
3. Final Lowering:
   1. Lower the vehicle completely.
   2. Lower and fasten the hood or cab according to the manufacturer's service manual.
   3. Remove the wheel chocks. 
4. Final Verification and Road Test:
   1. Verify Turns: With the engine running and the vehicle stationary, turn the steering wheel from the center position to the full right stop. Verify it is 2.5 revolutions. Return to center and verify the turn to the full left stop is also 2.5 revolutions.
   2. Check Centering: Drive the vehicle straight on a level surface to ensure the steering wheel is centered.
      1. Note: If the centering is off, it will need to be corrected. This is typically done by adjusting the length of the drag link or by removing and repositioning the steering wheel on the column splines.
   3. Road Test: Perform a final road test to check the overall steering feel and performance. Adjust as needed.