Disassembly

NOTE:
- Before disassembling the steering gearbox, wash it off with solvent and a brush.
- Do not dip seals and O-rings in solvent.

STEERING RACK
1. Remove the steering gearbox.
2. Remove the tie-rod end and locknut.





3. Remove the air tube and clips.





4. Remove the boot bands and tie rod clips. Pull the boots away from the ends of the gearbox.





5. Hold the steering rack with a wrench, and unscrew the rack end with another.

CAUTION: Be careful not to damage the rack surface with a wrench.





6. Loosen the locknut, then remove the rack guide screw and O-ring.
7. Remove the spring and the rack guide from the gearbox housing.





8. Remove the cylinder lines A and B from the gearbox.
9. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth.





10. Remove the two flange bolts, then remove the valve body unit from the gearbox.





11. Drill a 3 mm (0.12 inch) diameter hole approximately 2.5 - 3.0 mm (0.10 - 0.12 inch) in depth in the staked-point on the cylinder.

NOTE:
- Do not allow metal shavings to enter the cylinder housing.
- After removing the cylinder end, remove any burrs at the staked point.





12. Install a puller yoke to the steering gearbox. Clamp the puller yoke in a vise with soft jaws as shown, then loosen and remove the cylinder end.

CAUTION: Do not clamp the cylinder housing.

13. Set the steering gearbox in a press so the gearbox housing points upward.





14. Place a 6" long, 3/8" drive extension in the steering rack, and press the cylinder end and steering rack out of the gearbox.

NOTE: Hold the steering rack to keep it from falling when pressed clear.

CAUTION: Be careful not to damage to inner surface of the cylinder housing with the tool.





15. Turn the special tool so it will fit through the end of the gearbox housing, then position special tool on the backup ring as shown.

NOTE: Make sure that the special tool is securely positioned on the backup ring edges.





16. Insert a 24" long 3/8" drive extension into the cylinder and the special tool from the Gearbox side.
17. Set the gearbox housing in a press, then press out the cylinder end seal and backup ring from the gearbox housing.

CAUTION:
- Keep the tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it if necessary, when removing the cylinder end seal.
- Use a press to remove the cylinder end seal. Do not try to remove the seal by strikh1g the tool. It will break the backup ring, and the cylinder end seal will remain in the gearbox.

18. Check the rubber stop for damage or deterioration. If it is OK, go on step 20; if not, replace the rubber stop as shown:





19. Remove the rubber stop by prying it out of the gear box housing with a flat tip screwdriver.

CAUTION: Protect the pry point on the gearbox housing with shaft towel.





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

CAUTION: Be careful not to damage the inside of seal ring groove and piston edges when removing the seal ring.

VALVE BODY UNIT





1. Before disassembly the valve body unit, apply vinyl tape to splines of the pinion shaft. Remove the pinion dust cover.





2. Separate the valve housing from the pinion shaft/valve using a press.





3. Check the inner wall of the valve housing where the seal ring slides with your finger. If there is a step in the wall, the valve housing is worn. Replace the valve housing.

NOTE:
- There may be the sliding marks from the seal ring on the wall of the valve housing. Replace the valve housing only if the wall is stepped.
- When the valve housing is replaced, install new 32 mm shim(s) on the bearing surface of the housing to adjust the thickness.





4. Check for wear, burrs and other damage to the edges of the grooves in the sleeve.

NOTE: The pinion shaft and sleeve are a precision matched set. If either the pinion shaft or sleeve must be replaced, replace both parts as a set.





5. Remove the circlip and sleeve from the pinion shaft.





6. Using a cutter or an equivalent tool, cut and remove the four seal rings from the sleeve.

CAUTION: Be careful not to damage the edges of the sleeve grooves and outer surfaces when removing the seal rings.





7. Using a cutter or an equivalent tool, cut the valve seal ring and O-ring at the groove the pinion shaft. Remove the valve seal ring and O-ring.

CAUTION: Be careful not to damage the edges of the pinion shaft groove and outer surfaces when removing the valve seal ring and O-ring.





8. Remove the valve oil seal and backup ring from the pinion shaft.

NOTE:
- Inspect the ball bearing by rotating the outer race slowly. If there is any excessive play, replace the pinion shaft and sleeve as an assembly.
- The pinion shaft and sleeve are a precise fit; do not intermix old and new pinion shafts and sleeves.





9. Press the valve oil seal and roller bearing out of the valve housing using a hydraulic press and the special tool.