Disassembly

1. Remove the valve body unit.
2. Carefully clamp the gearbox in a vise with soft jaws.
3. Loosen the bands, pull the boots away from the ends of the gearbox, and unbend the tie-rod lock washers.

Removing Tie Rods From Steering Rack:

4. Hold the rack with a 22 mm wrench, and unscrew the tie-rods with a 17 mm wrench.

Push Cylinder Back Into Housing:

5. Push the right end of the rack back into the cylinder housing so the smooth surface that rides against the seal won't be damaged.

Removing Rack Guide Screw:

6. Loosen the rack screw locknut, and remove the rack guide screw, spring and rack guide.

Removing Snap Ring:

7. Remove the 28 mm snap ring from the bottom of the gear housing.

Removing Pinion From Gear Housing:

8. Remove the pinion from the gear housing by tapping it lightly.

Checking Pinion Ball Bearing:

9. Check the pinion lower ball bearing for play; if it is good, go on step 10. If the bearing is noisy or has excessive play, replace the bearing.

^ Remove the 12 mm snap ring.

Removing Pinion Ball bearing:

^ Remove the pinion lower ball bearing using a commercially available bearing puller.

Installing Pinion Lower Ball Bearing:

^ Using a press, install the pinion lower ball bearing on the pinion.

Checking Pinion Lower Bearing:

^ Apply grease and check the pinion lower ball bearing for smooth operation and install the 12 mm snap ring.

10. Remove the four cylinder bolts from the end of the cylinder housing, then slide the housing oft the rack.
11. Remove the cylinder housing.

Removing Cylinder Housing:

12. Remove the O-ring, back-up ring, steering rack bushing A and cylinder spring.

Removing Cylinder End Seal:

13. Remove the cylinder end seal from the cylinder housing.

NOTE: Use your fingers or a wooden stick to avoid damaging the housing.

Removing Steering Rack From Gear Housing:

14. Remove the cylinder, cylinder seal retainer, cylinder cap and steering rack from the gear housing.

Retainer Washer Removal:

15. Remove the retainer washer from the gear housing.
16. Remove the gear housing cap from the gear housing by removing the four 6 mm flange bolts.

Removing Steering Pinion Seal:

17. Remove the steering pinion seal from the gear housing cap.
18. Remove the O-ring from the gear housing.
19. Check the pinion holder for free movement, excessive play and rough movement; if it is in good condition go on step 20. If it is damaged, or if dirt has gone past the seal into the grease, replace the bearing.

Snap Ring Removal:

^ Remove the 30 mm snap ring from the pinion holder.

Pinion Holder Removal:

^ Remove the pinion holder from the gear housing.

Removing Bearing From Gear Housing:

^ Remove the pinion upper ball bearing from the gear housing.

Checking Needle Roller Bearings:

^ Check the needle roller bearing in the pinion holder and in the gear housing for damage; if they are OK, pack them "with grease. If the bearings are damaged, replace them as a set.

Installing New Pinion Bearing:

^ Drive the new pinion upper ball bearing into the gear housing using the special tools.

Installing Pinion Holder:

^ Install the pinion holder in the gear housing.

Align Snap Ring With Flat Area:

^ Reinstall the 30 mm snap ring with its tapered side facing out.

NOTE: Snap ring ends must be aligned with the flat area.

Removing Seal Retainer:

20. Remove the cylinder and seal retainer from the steering rack.
21. Remove the O-ring and snap ring from the seal retainer.
22. Remove the cylinder cap from the seal retainer.

O-ring Removal From Cylinder Cap:

23. Remove the O-rings from the cylinder cap.
24. Remove the bushing stopper ring from the seal retainer.

Removing End Seal And Rack Bushing "B":

25. Remove the cylinder end seal and rack bushing B.

Remove O-ring From Rack:

26. Carefully pry the piston seal ring and O-ring off the rack.