Dissembly, Inspection and Reassembly

Disassembly

Fig. 4 Exploded View Of Steering Gear Assembly:

1. Remove tie rod end from tie rod, then the dust cover from ball joint, Fig. 4.
2. Remove bellows band, then the retaining clip.
3. Pull bellows out toward tie rod. Check for rust on rack when bellows are replaced.
4. Remove feed tube from gear housing, then while slowly moving rack, drain fluid from gear housing.
5. Remove end plug, then with pinion turned clockwise until rack is locked, remove self-locking nut.
6. Unstake tab washer between tie rod and rack using a suitable chisel, then remove tie rod from rack. Use care to avoid twisting rack when removing tie rod.
7. Remove yoke plug locking nut, then the yoke plug using yoke plug socket 09565-21100 or equivalent.
8. Remove rack support spring and rack support yoke from gear box.
9. Remove valve body housing, then rotate rack stopper clockwise until end of circlip comes out of slot in gear housing. When end of circlip comes out of notched hole of housing rack cylinder, turn rack stopper counterclockwise and remove circlip.
10. Remove rack stopper, rack bushing and rack from gear housing by moving it toward pinion side.
11. Remove O-ring and oil seal from rack bushing.
12. Remove valve body from valve body housing using a soft face hammer, then using drift 09517-21400 or equivalent and a hammer, drive out oil seal and ball bearing from valve body housing.
13. Using drift and hammer, drive out ball bearing from gear housing. Ensure not to damage pinion valve cylinder inside of gear housing.
14. Using drift and hammer, drive out angular contact bearing from gear housing.
15. Using bar 09555-21000 and oil seal guide 09573-21200 or their equivalents, remove back washer and oil seal from gear housing. Ensure not to damage rack cylinder inside of gear housing.

Inspection

1. Check rack for excessive wear or damage tooth surface.
2. Inspect all oil seal contact surface for damage.
3. Check bearing for seizure, abnormal noise and excessive play.
4. Inspect dust cover for cracking or other damage.

Assembly

1. Apply Dexron II ATF to entire surface of rack oil seal, then using bar 09555-21000, oil seal guide 09573-21200, oil seal installer 09573-21100 and oil seal installer gauge 09573-21000 or their equivalents, install back-up washer and oil seal into gear housing.
2. Apply multi-purpose grease to entire surface of angular contact bearing, then set scribed side of bearing in drift 09432-21600 or equivalent and install into gear housing until drift contacts housing. Note direction of bearing.
3. Apply multi-purpose grease to ball bearing and install using drift 09222-21100 or equivalent. Always use a new bearing.
4. Apply Dexron II ATF to entire surface of rack bushing oil seal and O-ring, using counter shaft bearing installer 09434-142000 or equivalent, install oil seal into rack bushing, then the O-ring into rack bushing.
5. Apply multi-purpose grease to rack teeth, install rack into gear housing, wrap rack end with vinyl tape, apply a coating of Dexron II ATF, then install rack bushing and rack stopper.
6. Push in rack stopper until circlip groove of rack stopper is aligned with notched hole in rack housing, then install circlip while turning rack stopper. Ensure circlip end is not visible through notched hole of rack housing.
7. Install oil seal and ball bearing into valve body, then the seal rings in valve groove. Apply Dexron II ATF to seal rings.
8. Apply Dexron II ATF and multi-purpose grease to pinion valve assembly, then install into gear housing assembly.
9. Apply Dexron II ATF to seal, then using counter shaft bearing installer 09434-142000 or equivalent, install seal into valve body housing.
10. Install valve body assembly with seal ring onto gear box, then the tab washer and tie rod. Stake tab washer at two points over tie rod. Align tab washer pawls with rack groove.
11. With pinion turned fully clockwise, tighten new self-locking nut.
12. Apply semi-drying sealant to threaded section of end plug, then install and tighten to specifications. Stake end plug at two points on its circumference with a punch.
13. Install rack support yoke, rack support spring and yoke plug. Apply semi-drying sealant to threads of yoke plug.
14. With rack placed in center position, attach rack support cover to gear housing, then tighten rack support cover to 11 ft. lbs., loosen yoke plug approximately 30-60°, and tighten locking nut to specifications.
15. Tighten feed tube to specifications, then install mount rubber using a suitable adhesive.
16. Apply silicone grease to bellows fitting position of tie rod, then install new attaching band to the bellows.
17. Install bellows into position. Use care not to twist bellows.
18. Fill inside of dust cover with multi-purpose grease, then place dust cover into position with clip ring attached in groove of tie rod end.

Fig. 5 Tie Rod Installation:

19. Install tie rods until free length of left and right rods are 7.1 inches Fig. 5.