Disassembly

Fig. 3 Exploded View Of Steering Gear Assembly:

1. Remove tie rod end from tie rod, then the dust cover from ball joint, Fig. 3.
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 tool No 09565-31300, or equivalent, remove rack support cover.
8. Remove rack support spring, rack support and bushing from gearbox.
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 tool No. 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 tool No. 09573-33100 and bar tool No. 09555-21000, or equivalents, remove back washer and oil seal from gear housing.