ESACPC-3K661-AB (Tie Rod Boot Spec)

Engineering Specification
PART NAME: PART NUMBER:

SPECIFICATION - Boot / Bellows Rack & Pinion Steering Gear ESACPC-3K661- AB
LET
FR
LET
FR
DATE LET FR REVISIONS DR CK REFERENCE
24.Feb. Release ESACPC-3K661-AA SG

2014 AC00-E-12789352-000
Section III.A.5. Impact Resistance Test - Requirement, PREPARED/APPROVED BY
9 updated the height requirement from 1.0 m to 2.0 m.
CHECKED BY DETAILED BY
Section III.A.5. Impact Resistance Test - Test Method,
10 updated step "i" from 1.5m to 2.5m. J. Dalpiaz
CONCURRENCE/APPROVAL
SIGNATURES
DESIGN ENGINEERING SUPERVISOR
DESIGN ENGINEERING MGT.
OTHER APPROVAL/CONCURENCE
STEERING TECH SPECIALIST

T. Offerle
I. GENERAL
FRAME 1 OF 14 2014/02/24 AC00-E-12789352-000 ESACPC-3K661-AA
Quality Business Planning
GIS1 Item Number: 25.06
GIS2 Classification: Proprietary Version Date: 2008/01/15
FAF03-150-3 (previously form: 3947-A2)
This Global Generic Engineering Specification applies to the rack & pinion steering gear boot.
The function of the boot is to form a flexible seal between the steering gear housing and the tie
rod to prevent environmental contamination and moisture from entering the gear assembly.
This Engineering Specification is a supplement to the released drawing on the above part, and all
requirements herein must be met in addition to all other requirements of the part drawing.
The Engineering Specification is intended to evaluate specific characteristics as a supplement to

normal material inspections, dimensional checking, and in-process controls, and should in no
way adversely influence other inspection operations.
Preparation and submission of an acceptable Control Plan are the responsibility of the
manufacturing source. The manufacturing source will retain the original Control Plan and any
later revisions per Section 7.3 in FAP02-001, and provide a copy to the design-responsible
Product Engineering activity.
II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS

Production Validation (PV) tests are used to obtain an initial estimate of the process potential to
produce parts that conform to engineering requirements, and to identify causal or predictive
relationships between significant design and process characteristics (to be used for process
control). These tests must be completed satisfactorily using initial parts from production tooling
and processes, in accordance with PPAP requirements, before Part Submission Warrant (PSW)
approval and authorization of production parts is granted. Sampling plans for PV testing must be
included in the Control Plan.
In-Process (IP) tests are used to further understand the relationship between significant design
and process characteristics and to establish a basis for continuing improvement. Tests must be
completed with production parts on an ongoing basis. Sampling plans for both IP testing and
evaluation of the significant process characteristics must be included in the Control Plan. When
the process is found to be out of control or the test acceptance criteria are not met, the reaction
plan approved in the Control Plan shall be invoked.
The table that follows summarizes the various PV and IP tests and the acceptance parameters
for each. They form the basis on which to develop a complete Control Plan for these and their
related significant process characteristics. The Control Plan will include frequencies, sample
sizes and reaction plans; see Quality Management Systems, ISO/TS 16949:2002.

SUMMARY OF ES TEST AND ACCEPTANCE PARAMETERS
Test Test Test Low Target Upper Minimum Preliminary

Number Characteristic Use Tolerance Value Tolerance Conform- Control
Limit Limit ance to Plan
Tolerance Parameters
Clearance PV No Contact No Contact 30% of Wall No Contact
Requirement / 0% of Thickness / 0% of
Wall Abrasion Wall
Thickness Thickness
Abrasion Abrasion
1 Static Air Leak PV, IP No No No Leakage 6
Leakage Leakage
2 Underwater PV No water No water No water 6
Sealing ingress ingress ingress
3 Boot Durability PV Per Spec. Per Spec. Per Spec. 6
4 Torsion PV Per Spec. Per Spec. Per Spec. 6
5 Impact PV Per Spec. Per Spec. Per Spec. 6
6 Inclusion of PV Per Spec. Per Spec. Per Spec. 6
boot
7 Axial PV Per Spec Per Spec Per Spec 8
Compression
/Extension and
Pull-Off
8 Heat Deflection PV Per Spec Per Spec Per Spec 4
III. TEST PROCEDURES AND REQUIREMENTS
A. General Specification
Exposure Temperatures
Following are temperatures that the boot must operate in during testing and storage:
Min. Max
Room Operating Operating
(Tn) (T1) (T2)
Temperature
(°C) 23°C -40°C 120°C
Tolerance
(°C) +/- 10°C +/- 3°C +/- 3°C
Inner Tie Rod Angle

All angles referenced in this specification are to have a general tolerance of +/- 2° unless otherwise
specified.
Clearance Requirement
Objective
Check the extent of interference between the inner ball joint and the inner diameter of the boot.
This verification must be done:
• During the development of the original design. No contact should exist at the jounce,
design and rebound vehicle angles.
• After any design change of the boot or the inner tie rod and/ or after each design.
• After the completion of each test.
Requirement
At the end of each test, all boots must be inspected for signs of abrasion. Wall thickness
should be measured on boots with sign of abrasion. Failure or excessive abrasion is
considered if it exceeds 30% of the boot wall thickness. Pictures should be taken when any
deformation occurs, such as ballooning or thinning of the boot walls and area of failure must
be clearly identified, such as convolute #X. If no abrasion was found, each test results should
also indicate a statement such as: No Abrasion.
1. Static Air Leak Test
Objective
The purpose of this test is to examine air leakage of the boot at certain positive and negative
pressures.
Requirement
There shall be no evidence of air leakage from any portion of the boot or wall thinning as
indicated by localized ballooning of the surface.
Test Conditions
Test to be conducted at Tn with production representative parts, tooling, clamps and assembly
methods.
Suggested Test Fixture

The test fixture should be production representative of the steering gear including tie rod, boot,
rack, housing and clamps (See Figure 1). It must also include a pressure gage and
vacuum/pressure source. Pressure gage should have a resolution of 0.1psi or better.

Figure 1
Test Method
a. Assemble the boot test fixture using production grease as indicated on the gear assembly
print. Also, use the production-crimping tool to crimp the inner boot clamp and
recommended installation tool for the constant tension clamp. Set boot axial length to the
installed length per the boot print.
b. Apply pressure to the boot, rising gradually from atmospheric pressure to 29.4kPa (4.3psi).
c. Turn off pressure supply. Allow the pressure to stabilize for 30 seconds and maintain said
pressure for 10 minutes. A leak will be evident if pressure decreases during this time by
more than 0.2psi.
d. Release pressure gage and allow to return to atmospheric pressure.
e. Apply vacuum to the boot, gradually decreasing from atmospheric pressure to a vacuum of
29.4kPa (4.3psi).
f. Turn off vacuum supply. Allow the vacuum to stabilize for 30 seconds and maintain said
vacuum for 10 minutes. A leak will be evident if pressure increases during this time by
more than 0.2psi.
Reporting
Air leakage takes place when there is a change in the constant pressure state. Take pictures of
any noticeable change, and record the pressure at which the change occurs.
2. Underwater Sealing Test
Objective
The purpose of this test is to verify the sealing capability of the boot, while fully compressed and
extended, to the housing and tie rod.
Requirement
No water infiltration into the boot after the test.
Test Conditions

The water should be held at Tn throughout the test. The boot should be cycled to simulate a rack
speed of 10.5 – 14.5 mm/sec. During the test, the tie rod angles should be changed so that the test
is run with the tie rod angle at design position 50 % of the time and at jounce/rebound position
both 25% of the time.

rack, housing and clamps such that the boot will be extended and compressed in design, jounce
and rebound vehicle angles in a water bath.
Test Method
a. Mount the test fixture in a water bath so that the rack centerline is 100mm under the
surface.
b. Cycle the boot 1000 times underwater through 80% of stroke in both extended and
compressed directions. If tie rod does not naturally stay in position, some type of support
will be needed.
c. Upon termination of test, inspect boot for leaks and interior moisture. Fluorescent dye may
be used in the water to aid inspection process.
d. Set boots tested aside to continue running part 2, the Durability Test.
Reporting
Take pictures of any cracks, tears or holes that would have caused water infiltration. Record
any observations of moisture inside the boot.
3. Durability Test
Objective
The objective of this test is to check the occurrence of damage such as cracking and wear with
articulation and sliding motions applied to the boot at ambient, low, and high temperature and
high temperature with salt spray.
Requirement
There shall be no evidence of splits, tears or contamination entering the inside of the boot past
the sealing surfaces and no evidence of air leakage.
Test Conditions
e. All the instruments, apparatus and parts that will be used should be maintained at room
temperature for at least 24hrs prior to testing and should be the same as those used in
actual vehicles.
f. An example of angular amplitude of articulation and sliding motion applied to the boot is
shown graphically in Figure 2. The angular amplitude is obtained from the vehicle ride
height data: Max=Rebound Straight Ahead Angle and MIN=Jounce Straight Ahead
Angle. The sliding amplitude shall be 10mm greater than the designed steering gear rack
stroke shown on the gear assembly print (5mm less in full compression and 5mm more in
full extension).
g. The articulation frequency must be 3.0 Hz.
h. The sliding frequency must be 1.0 Hz.
i. Set the boot axial length to the installed length per the boot print.
j. The temperature requirements are Tn, T1, and T2.
k. Vent boots outside the chamber to allow for pressure equalization during cycling.

18
16
14
12
10
8
6
4
2
ITR Travel (deg)
0
-90 -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90
-2
-4
-6
-8
-10
-12
-14
-16
-18
-20
-22
-24
Rack Travel (mm)
Figure 2
rack, housing and clamps such that the boot will be extended and compressed in design, jounce
and rebound vehicle angles. The fixture must have the capability to axially travel to the rack
stroke shown on the gear assembly print plus 10mm min. in both directions. It is suggested to
use two separate motors. It should also be designed to fit an enclosure capable of maintaining
temperatures from T1 to T2. It is advisable to build the test fixture capable of testing four
boots simultaneously. A pressure port is required thru the rack for internal pressurization.
See Figure 3 below.
Pressure Port
Figure 3
Test Method

l. Prior to installation, cycle any constant tension clamps to fully open position ten times per
the clamp print using recommended tool. Mount the boots, tie rod, and clamps on the test
fixture.
m. A total of 112,500 cycles are to be run in the following sequence:
i. Soak the fixture at T1 for a minimum of 2 hours prior to cycling.
ii. At the end of the soak period begin cycling and maintain a negative internal boot
pressure (vacuum) of -7.0 kPa ±3.5 kPa (-1.0 psi ±0.5psi), run 5,000 tie rod
articulation cycles at T1
iii. Vent the internal boot pressure to atmosphere, continue to cycle while raising the
temperature to Tn over a period of approximately 60 minutes and run 45,000 tie rod
articulation cycles.
1. Spray the boot in a minimum of 3 places which are to include the boot to
housing and boot to tie rod interface with a 5% salt and 50 micron mesh grit (14
cc of grit per liter of solution or other solution that contain salt) for 1 minute
every 6 minutes. Deliver the spray at approximately 0.5 gal/min.
iv. Again, continue to cycle while raising the temperature T2 over a period of
approximately 60 minutes, maintain a positive internal boot pressure of 21.0kPa
±7kPa (3.0 psi ± 1.0 psi) and run 62,500 tie rod articulation cycles.
v. At the completion of 62,500 cycles, vent the internal boot pressure to atmosphere
lower the temperature to T1 and repeat i-iv.
n. Stop the test at every temperature change and inspect the boot for abnormalities, take
pictures and record the condition of the boots.
o. Discontinue the durability test if through cracking, collapsing, wear or failure is observed
on the boot.
p. Check the boots for cracking, tears, wear, etc. after the durability test is completed by
running the static air leak test per section III.A.1.a-d. Pressure needs to stabilize only,
holding for 10 minutes is not required.
q. Take pictures of the boots to record the location and degree of cracks, wear or failure and
report.
Reporting
Record condition of boots and include pictures as specified in test method.
4. Torsion
Objective
Verify the time when the boot returns to its original position after the tie rod is rotated 360o.
This is to simulate the toe set operation at the vehicle assembly plant and in service.
Requirement
Boot shall unwind and return to original position or less than 5° of original position, within 5
seconds.
Test Conditions
The test should be performed at Tn.

Assemble the boot to the steering gear, including inner and outer boot clamps. The steering
gear should be mounted in a holding fixture capable of measuring the angle of twist the boot
encounters.
Test Method
a. Evaluate half of the samples rotating the boot clockwise and half by rotating
counterclockwise.
b. Mark tie rod end of boot and the tie rod in order to measure rotation.
c. Rotate inner tie rod 360, hold for 10 seconds.
d. Record time required for boot to unwind and return to within 5° of its original position.
Indicate if the boot does not return to its original position and/or if the time to unwind
is greater than 5 seconds.
e. Repeat the test procedure (a to d) on the same parts after the boots sit for 14 days.
Reporting
Record results in a table, providing the angles and times as specified above.
5. Impact Resistance Test
Objective
The objective of this test is to examine the impact/puncture resistance of the boot.
Requirement
The boot must withstand an impact from 2.0m or higher after dropping a steel ball onto its
thinnest section.
Test Conditions
Weight: 227g
Drop height: 800mm (measured from the topside of the boot valley)
Ball size: 38.1mm diameter
Tie Rod angle: Max Rebound Straight Ahead (deg)
Weight falling direction: Perpendicular to the rack bar
The impact point should be in the valley of the boot vertically above the ball joint at the
thinnest part. The boot should be set to the max extension as specified on the boot print.

Secure a rack tube assembly on a stand, holding the tie rod at an angle that stretches the boot
and allows the ball to be dropped into the valley of the boot at the thinnest part. Use a
mechanism in which a weight is dropped to impact the boot. An example of a fixture is shown
in figure 4.

Figure 4
Test Method
a. Mount the boot on the boot fixture.
b. Set the boot at maximum extended length per the boot print and the tie rod at max straight
ahead rebound angle.
c. Make sure that the boot valley being tested is directly above the tie rod ball joint socket
housing (see figure 4).
d. Set the weight to the required height and release it onto the boot valley.
e. Analyze the boot for cracks, dents and cuts at the point of impact.
f. Repeat steps d and e. four more times for a total of five drops at each height.
g. Perform a static air leak check per section III.A.1.a-d. Pressure needs to stabilize only,
holding for 10 minutes is not required. This will verify when the boot wall has been
broken through or whether to continue testing.
h. Maintaining the boot in the same location, increase the drop height by 0.1m (100mm)
starting at 0.8m. The boot shall not be replaced or rotated.
i. Repeat steps d through h. Terminate the test when the first crack or cut is noted or when
the height of 2.5m is reached. Take a picture of the affected area.
Reporting
Record the distance v. number of drops on a table as shown in the example below. Include a
picture of the damaged area.
Sample Drop Number of Drops

P= Passed
Height (m) Impact 1 Impact 2 Impact 3 Impact 4 Impact 5 F= Failed
1 0.8 P P P P P
0.9 P P P P P
1.0 P F
1.1

6. Inclusion of Boot
Objective
The purpose of this test is to examine inclusion of the boot at various temperatures and tie rod
angles.
Requirement
No inclusion of the boot at the termination of the test. Inclusion is defined as any dimples,
kinks or permanent deformations created on the boot throughout the test.
Test Conditions
The heat treatment of the boot is a 7 hour pattern with varying temperatures. Vent the boot for
equalization of pressure.

The test fixture should be capable of cycling the gear or gear equivalent at different tie rod
angles. The fixture should be contained in a chamber capable of maintaining temperature
changes.
Test Method
a. Set the gear at the tie rod angle of 28 degrees.
b. Carry out 10 cycles of the heat treatment pattern that follows:
1. 3 hours at T1
2. ½ hour at Tn
3. 3 hours at T2
4. ½ hour at Tn
c. At each tie rod angle specified, (0, 10, 20, 25 and 28 degrees), apply an axial force to pull
the boot full stroke from fully compressed to fully extended while raising the axial speed
from zero to 0.152 m/s in increments of 0.02 m/s.
d. Check the presence of inclusion in the boot.
Reporting:
Take pictures of the boot after test, checking for inclusion.
7. Axial Boot Compression/Extension and Pull-Off Test
Objective
The objective of the axial compression/extension test is to verify the force required to axially
compress and extend each boot and the pull-off test is to verify the force to pull the boot from
the housing while it is clamped.
Requirement
Force required to compress and extend each boot shall be less than 300N and the pull off force
of the boot from the housing and boot to tie rod shall exceed 2 times the highest extension load
as measured in this procedure.

rack, housing and clamps such that the boot will be extended and compressed. The fixture must
have the capability to axially travel to the rack stroke shown on the gear assembly print plus 5mm
min. in both directions and must allow the boot to stretch 2 to 3 times its normal length. The
fixture must also be capable of plotting force vs. distance when measuring compression and
extension forces.
Test Method
a. Assemble the boot test fixture using production grease at the boot to housing interface and
the boot to tie rod interface, if applicable (refer to gear assembly print for grease and
amount). Also use the production-crimping tool to crimp the inner boot clamp per the load
specified on the gear assembly print. Set boot axial length to the installed length per the
boot print with the tie rod articulation at 0°.
b. Prepare half of the samples to run at Tn and the other half to run at T1 (2 hour soak prior to
beginning test).
c. Maintaining temperature, measure and plot (force vs. distance) the force necessary to
totally compress each boot within 5mm of the compressed length shown on the boot print.
d. Return the boot to the installed length, measure and plot (force vs. distance) the force
necessary to totally extend the boot within 5mm of the extended length shown on the boot
print.
e. Apply an axial load using the inner tie rod, starting at zero, on the boot in the direction
away from the housing.
f. Measure the force required to pull the boot off the steering gear housing or off the tie rod.
Reporting
Record the compression and extension force via a force vs. distance plot and the pull off force.
8. Heat Deflection Test
Objective
Survey the amount of residual deformation of the boot under various temperature conditions.
Requirements
Deflection must not result in the boot touching the adjacent tie rods or racks. All boots must
meet boot print dimensions post test.

rack, housing and clamps. (See Figure 5) It must also be able to cycle the system through full
rack travel in a climate-controlled chamber.

Test Method
a. Assemble the boots and necessary components into the test fixture. Set the length at the
Figure 5
maximum extended length called out on the boot assembly print and the articulation angle
of 0o.
b. Heat the boot in the temperature chamber to T2.
c. Soak the boot at the specified temperature for 8 hour.
d. Remove the test apparatus from the chamber and cool for 2 hours.
e. Measure the deformation and photograph the boot as set on the test apparatus.
f. Perform a complete dimensional check on the boots.
Reporting
Record the dimensions of the parts and include pictures noting any deformation of the boots.
IV. REVALIDATION REQUIREMENTS

The conditions requiring revalidation include changes in part design, material (or source), or
manufacturing process that could affect part function, performance or durability. Examples of specific
revalidation requirements statements follow:
The manufacturing source and the design-responsible Product Engineering activity will jointly determine
which potential changes to the process, materials or material sources would have significant impact on
the product’s function, performance, durability or appearance. The supplier will describe these
conditions in the Control Plan, along with either (1) the revalidation plan that would be followed in each
case, or (2) a provision to submit an amended Control Plan for approval if any of those process changes
are planned.
No change to processing may be allowed without prior engineering approval of the process changes and
the attendant Control Plan changes.
V. INSTRUCTIONS AND NOTES

Control Plans address all significant design and process characteristics, which include all ES tests and
Control Item characteristics. They describe the process potential studies that will be performed for
product validation (including PV tests) and the ongoing product and process evaluation for continuing
improvement (including IP tests). They include acceptance criteria, sample sizes, frequencies, data
analysis methods and reaction plans.
The Control Plan is developed, and updated as necessary, by the manufacturing source in conjunction
with the design responsible Product Engineering activity and other appropriate functions. The Control
Plan defines the management of the upstream production process and part variables (significant
process characteristics) that affect the outcome of the ES tests or other significant design
characteristics. The Control Plan also identifies the specific ES tests, with their sample sizes and
frequencies, that will be performed in order to:
• Confirm whether the process is being managed effectively.
• Further identify significant process characteristics.
• Evaluate performance of marginal processes.
• Better anticipate the customer effect of proposed process improvements.
For any part on which ES tests have been specified, the manufacturing source must present the Control
Plan and any revisions to the design responsible Product Design activity for review. This Product
Engineering activity has flexibility to honor business relationships with suppliers having proprietary
processes.
Examples of formats for Control Plans are shown in the AIAG Advanced Product Quality Planning and
Control Plan (APQP) Guidelines. Copies of all PV test results are to be sent to the Ford Motor Company
Product Development Engineer.
Note: Outside suppliers should request all reference information from the Product Engineering activity.


ESACPC-3K661-AB (Tie Rod Boot Spec)

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ESACPC-3K661-AB (Tie Rod Boot Spec)

Uploaded by

Copyright:

Available Formats

Engineering Specification

PART NAME: PART NUMBER:

DATE LET FR REVISIONS DR CK REFERENCE

24.Feb. Release ESACPC-3K661-AA SG

DESIGN ENGINEERING MGT.

STEERING TECH SPECIALIST

The Engineering Specification is intended to evaluate specific characteristics as a supplement to

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS

FRAME 2 OF 14 2014/02/24 AC00-E-12789352-000 ESACPC-3K661-AA

SUMMARY OF ES TEST AND ACCEPTANCE PARAMETERS

Test Test Test Low Target Upper Minimum Preliminary

III. TEST PROCEDURES AND REQUIREMENTS

Inner Tie Rod Angle

FRAME 3 OF 14 2014/02/24 AC00-E-12789352-000 ESACPC-3K661-AA

1. Static Air Leak Test

Suggested Test Fixture

FRAME 4 OF 14 2014/02/24 AC00-E-12789352-000 ESACPC-3K661-AA

2. Underwater Sealing Test

FRAME 5 OF 14 2014/02/24 AC00-E-12789352-000 ESACPC-3K661-AA

Suggested Test Fixture

FRAME 6 OF 14 2014/02/24 AC00-E-12789352-000 ESACPC-3K661-AA

FRAME 7 OF 14 2014/02/24 AC00-E-12789352-000 ESACPC-3K661-AA

Suggested Test Fixture

5. Impact Resistance Test

Suggested Test Fixture

FRAME 9 OF 14 2014/02/24 AC00-E-12789352-000 ESACPC-3K661-AA

Sample Drop Number of Drops

FRAME 10 OF 14 2014/02/24 AC00-E-12789352-000 ESACPC-3K661-AA

Suggested Test Fixture

7. Axial Boot Compression/Extension and Pull-Off Test

Suggested Test Fixture

8. Heat Deflection Test

Suggested Test Fixture

FRAME 12 OF 14 2014/02/24 AC00-E-12789352-000 ESACPC-3K661-AA

IV. REVALIDATION REQUIREMENTS

V. INSTRUCTIONS AND NOTES

FRAME 14 OF 14 2014/02/24 AC00-E-12789352-000 ESACPC-3K661-AA

You might also like