Disassembly

CAUTION:
^ Before disassembling the gearbox, wash it off with solvent and a brush.
^ Thoroughly clean all disassembled parts.
^ Always replace O-rings and seals.
^ Replace parts with damaged sliding surfaces.
^ Do not dip seals and O-rings in solvent; coat O-rings with grease or power steering fluid, make sure they stay in position during reassembly, and use the appropriate special tools to install them where necessary.


1. Remove the O-ring from the valve body unit.
2. Remove the three 6 mm flange bolts, and remove the valve body cap from the valve body.

Cap Seal Removal:

3. Remove the cap seal from the valve body cap.

Pressure Control Valve And Spring Removal:

4. Remove the pressure control valve and spring from the valve body.

Checking Pressure Control Valve:

5. Check the pressure control valve:

^ Inspect its surface for scoring or scratches.
^ Slip it back into the valve body, and make sure it slides smoothly without drag and without side play.

NOTE: If the valve body is damaged, replace the valve body unit valve body, pressure control valve, gain control valve, 4-way valve) as an assembly.

Gain Control Valve And Spring Removal:

6. Remove the gain control valve and spring from the valve body.

Checking Gain Control Valve:

7. Check the gain control valve:

^ Inspect its surface for scoring or scratches.
^ Slip it back into the valve body and make sure it slides smoothly without drag and without side play.

NOTE: If the valve body is damaged, replace the valve body unit (valve body, pressure control valve, gain control valve, 4-way valve) as an assembly.

8. Separate the valve body and port housing.

Port Seal And Dowel Pin Removal:

9. Remove the port seal and dowel pins from the port housing.

Roller Removal From 4-way Valve:

10. Remove the rollers from the 4-way valve by pushing the valve out one side of the valve body, and then the other.

NOTE: When removing the rollers. hold the plungers with your fingers to keep them from popping out.

11. Remove the plungers, return springs and 4-way valve from the valve body.
12. Remove the 11 mm O-ring from the 4-way valve.

Plunger Inspection:

13. Check the plungers.

^ Inspect their surface for scoring or scratches.
^ Slip each plunger into the valve body, and make sure it slides smoothly, without drag or side play. If any plunger is damaged, replace it.

Checking The 4-way Valve:

14. Check the 4-way valve.

^ Inspect its surface for scoring or scratches.
^ Slip it into the valve body, and make sure it slides smoothly, without drag or side play.

NOTE: If the valve body is damaged, replace the valve body unit (valve body, pressure control valve, gain control valve, control valve) as an assembly.

Removing Sensor Orifice:

15. Using a 3 mm (1/64") drill bit, remove the sensor orifice and 3.4 m O-ring.