Dissembly, Inspection and Reassembly

Disassembly

Fig. 2 Exploded View Of Steering Gear Assembly:

1. Remove tie rod end from tie rod, then the dust cover from ball joint, Fig. 2.
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. Using a suitable hammer and chisel, remove tab washer securing tie rod to rack.
6. Remove tie rod from rack. Use care to avoid twisting tie rod when removing from rack.
7. Remove rack support cover locking nut, then using yoke plug socket 09565-31300 or equivalent, remove rack support cover.
8. Remove rack support spring, rack support and bushing from gear box.
9. Remove end plug and snap ring with suitable pliers.
10. Remove pinion and valve assembly with upper oil seal, using a soft hammer.
11. Rotate rack stopper clockwise until end circlip is removed from slot in gear housing, then turn rack counterclockwise and remove circlip.
12. Remove rack stopper, rack bushing and rack from gear housing by moving it toward the piston side.
13. Remove O-ring and oil seal from rack bushing, then the oil seal from rack bushing.
14. Using a drift and hammer 09517-21400 or equivalent, drive out ball bearing. Ensure not to damage the pinion valve cylinder inside of gear housing.
15. Drive out needle bearing and oil seal.
16. Using oil seal guide 09573-33100 and bar 09555-21000 or equivalent, remove back washer and oil seal from 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 a suitable oil to entire surface of oil seal for rack.
2. Using oil seal installer 09573-33000 and guide 09573-33100 or equivalent, install back-up washer and oil seal in gear housing.
3. Apply suitable lubricant to surface of needle bearing, then using valve stem oil seal installer 09222-21100 or equivalent, install needle bearing in gear housing. Note direction of needle bearing.
4. Using a front seal installer 09431-11000 or equivalent, place inscribed side of oil seal in the gear housing.
5. Apply suitable lubricant to rack bushing oil seal surface, then install seal into rack bushing.
6. Insert rack bushing O-ring, the apply a suitable lubricant to rack teeth. Do not plug vent hole in rack with grease.
7. Insert rack into gear housing, then install rack bushing and rack stopper.
8. Push rack stopper until circlip groove is aligned with notched hole in housing, then insert circlip while turning rack stopper, Ensure circlip end is not visible through notched hole of rack housing.
9. Apply suitable lubricant to pinion valve assembly, then install to gear housing.
10. Using valve stem oil seal installer 09222-21100 or equivalent, install ball bearing then pinion and valve assembly to valve housing.
11. Using bearing installer 09432-21601 or equivalent, install oil seal and snap ring.
12. Rotate pinion fully clockwise, then tighten new self-locking nut.
13. Apply suitable sealant to threaded section of end plug. Tighten to specifications.
14. Stake end plug at two points using a suitable punch, then install new tab washer and tie rod. Peen tab washer end at two points to tie rod.
15. Install bushing, rack support, spring, and rack support cover. Apply suitable lubricant to threaded section of rack support prior to installation.
16. Place rack at center position, then torque rack support cover to 8 ft. lbs. Loosen cover approximately 30-60°, then tighten locknut to specifications.
17. Tighten feed tube, then install mount rubber using a suitable adhesive.
18. Apply suitable lubricant to bellows fitting position of tie rod, then install new attaching band to the bellows.
19. Fill inside of dust cover with a suitable lubricant, then place dust cover into position with clip ring attached to groove at tie rod end.

Fig. 3 Tie Rod Installation:

20. Install tie rods until free length of left and right rods are 7.38 inches Fig. 3.