Overhaul
DISASSEMBLEFig. 21 Exploded View Of Front Steering Gear:
Fig. 22 Installing Circlip Into Pinion Holder:
1. Remove two valve body unit to gearbox attaching bolts.
2. Remove O-rings and port orifices from gearbox.
3. On models with 2 wheel steering, loosen rack screw locknut and remove rack guide screw.
4. On models with 4 wheel steering, loosen rack screw locknut and remove rack guide screw/sub steering angle sensor assembly.
5. On all models, remove spring and rack guide from gear housing.
6. On models with 4 wheel steering, remove rack guide screw, O-ring and locknut from sub steering angle sensor.
7. On all models, carefully clamp gearbox into a vise with soft jaws.
8. Remove tie rod assembly, then the boot bands and tube clamps.
9. Pull dust seals away from ends of gearbox.
10. Hold steering rack with a wrench and unscrew rack end, then remove the dust cover.
11. Remove four gear housing cap to gear housing attaching bolts, Fig. 21.
12. Remove steering pinion seal from gear housing cap.
13. Push right end of rack back into cylinder housing so the smooth surface that rides against the seal will not be damaged.
14. Check pinion lower bearing for play. If there is no play and grease is satisfactory, proceed to step 15. If bearing is noisy or has excessive play, proceed as follows:
a. Remove snap ring from pinion assembly.
b. Using a suitable bearing puller, remove bearing from pinion assembly.
c. Using a suitable press, press new bearing onto pinion assembly.
d. Install snap ring onto pinion assembly.
15. Remove four bolts from end of cylinder assembly.
16. Remove O-ring back-up ring, steering rack bushing ``A,'' cylinder spring and cylinder end seal from cylinder housing.
17. Remove cylinder, cylinder seal retainer, cylinder cap, steering rack and retainer washer from gear housing.
18. Check pinion holder for free movement, if movement is satisfactory, proceed to step 19. If there is excessive play or movement is rough, proceed as follows:
a. Remove circlip from pinion holder.
b. Remove pinion holder from gear housing.
c. Check needle roller bearings in pinion holder and gear housing for damage, if bearings are satisfactory, repack them with grease. If bearing are worn or damaged, replace them as a set.
d. Check lower ball bearing for damage, if bearing is satisfactory, proceed to step 19. If lower ball bearing is damaged, remove bearing from gear housing.
e. Using driver tool No. 07749-0010000 and attachment No. 07746-0010300 or equivalents, drive new lower bearing into gear housing.
f. Install pinion holder in gear housing.
g. Install circlip into pinion holder with its tapered side facing outward. Circlip ends must be aligned with flat area as shown in Fig. 22.
19. Remove cylinder and seal retainer from steering rack.
20. Remove O-ring, snap ring and cylinder cap from seal retainer.
21. Remove O-rings from cylinder cap, then the bushing stopper ring from seal retainer.
22. Remove cylinder end seal and rack bushing ``B'' from steering rack.
23. Carefully pry piston seal ring and O-ring off of rack.
ASSEMBLE
1. Install new O-ring on rack with its narrow edge facing out.
2. Coat pinion seal ring guide with power steering fluid, then slide onto rack, big end first.
3. Position new piston seal ring on piston seal ring guide too No. 07LAG-SM40100 or equivalent, slide seal ring onto big end of tool, then pull it off into piston groove on top of O-ring.
4. Coat piston seal ring and piston seal ring sizing tool No. 07LAG-SM40200 or equivalent with power steering fluid.
5. Carefully slide tool onto rack and over piston ring, then rotate tool as you move it up and down to seat piston ring.
6. Coat new O-rings with grease, then install them onto cylinder cap.
7. Slide cylinder cap onto seal retainer.
8. Install snap ring and O-ring on seal retainer.
9. Grease sliding surface of steering rack bushing ``B,'' then install bushing on steering rack with groove of bushing facing steering rack piston.
10. Grease sliding surfaces of new cylinder end seal and cylinder end slider tool No. 07LAG-SM40300 or equivalent, then place seal on tool with its grooved side facing opposite slider.
11. Install tool and cylinder end seal on rack. Ensure that rack teeth do not face slot in tool.
12. Separate cylinder end seal from tool, then remove tool from rack.
13. Fit seal retainer on steering rack.
14. Push rack bushing ``B'' toward seal retainer until cylinder end seal is seated in retainer. Fit seal stopper ring in groove of seal retainer securely, then grease rack.
15. Install retainer washer on gear housing.
16. Place gear housing on bench and insert seal retainer and steering rack into gear housing.
17. Coat inside surface of cylinder with power steering fluid, slide it over rack and into gear housing, then press in into housing until it seats.
18. Install cylinder spring over rack, then coat bushing ``A'' with power steering fluid and install it onto spring.
19. Wrap end of steering rack with vinyl tape, then coat tape with grease.
20. Coat inside surface of cylinder with power steering fluid, then install cylinder end seal with its grooved side facing out.
21. Install O-ring and back-up ring on gear housing.
22. Carefully position cylinder on gear housing and loosely install four bolts. Be careful no to damage end seal of cylinder housing.
23. Remove vinyl tape from steering rack.
24. Make sure mating surfaces of the gear housing and cylinder housing are aligned by pushing them together, then while holding them together, torque four attaching bolts to 16 ft. lbs.
25. Insert steering rack into cylinder housing, being careful not to damage steering rack sliding surface.
26. Install steering pinion into pinion holder, then the circlip securely into pinion holder groove with its tapered side facing outward.
27. Grease sealing lip of steering pinion seal, then install it onto gear housing.
28. Wrap spline area of steering pinion with vinyl tape and grease surface of tape.
29. Grease new O-ring and install it into gear housing.
30. Slide gear housing cap over steering pinion, being careful not to damage sealing lip or dislodge pinion seal spring.
31. Torque gear housing cap attaching bolts to 8 ft. lbs.
32. Remove vinyl tape from steering pinion, then install new lock washer in groove of steering rack.
33. Holding steering rack with a wrench, Torque rack end to 47 ft. lbs.
34. After tightening rack end, stake lock washer in four places.
35. Apply steering grease to circumference of rack end housing.
36. Coat rack end groove and inside of boot with silicone grease.
37. Install boots on rack end with tube clamps.
38. Install tie rod ends, torque tie rod end locknut to 33 ft.lbs.
39. Grease new O-ring and install it in groove of rack guide screw.
40. Coat rack guide sliding surface with grease, then install rack guide, spring and rack guide screw onto gear housing.
41. Adjust rack guide at center of rack stroke.
42. On models with 2-wheel steering, proceed as follows:
a. Tighten rack guide screw until it compresses spring and seats against rack guide, then loosen it.
b. Torque rack guide screw to 34 inch lbs. and back it off approximately 20°, then install locknut on rack guide screw.
c. Using a suitable tool to hold the rack guide screw, tighten locknut.
43. On models with 4-wheel steering, proceed as follows:
a. Install locknut on sub steering angle sensor.
b. Grease a new O-ring and install it in groove of sub steering angle sensor.
c. Install rack guide screw, then coat rack guide sliding surface with grease.
d. Install rack guide, spring, O-ring and front sub steering angle sensor on gear housing, then adjust rack guide at center of rack stroke.
e. Tighten rack guide screw until it compresses the spring and seats against rack guide, then loosen it.
f. Torque rack guide screw to 36 inch lbs, then back it off approximately 20° and install locknut on rack guide.
g. While holding guide screw, Torque locknut to 18 ft. lbs.
44. On all models, coat O-rings with grease and install them together with the orifices.
45. Coat O-ring and pinion holder pin with grease, then install into valve body unit.
46. Install valve body unit onto gear housing, torque attaching bolts to 16 ft. lbs. When installing valve body unit, be careful not to hit pinion holder pin and ensure O-rings are in place and not pinched.
47. When installing boot band, ensure rack is in its straight ahead position.
Fig. 23 Installing Boot Bands Onto Steering Gear:
48. Install boot band so that locking tabs of the band are in range shown in Fig. 23.
49. Install new boot bands on the boot and bend both sets of locking tabs.
50. Lightly tap on doubled-over portions to reduce their height.
51. Install band cushion and air hose band, then position band as shown in Fig. 23 and tighten it.
52. Install air hose, then slide rack right and left to ensure that boots are not deformed or twisted.