Disassembly

Fig. 5 Exploded View Of Steering Gear Assembly:

2. Disconnect pressure hose and return tube, Fig. 5.
3. Remove joint assembly connecting bolt.
4. Using tie rod end puller tool No. 09568-31000, or equivalent, disconnect tie rod end from knuckle arm.
5. Remove center member assembly with front roll stopper.
6. Temporarily disconnect front muffler.
7. Remove stay and disconnect left lower arm.
8. Remove stabilizer bar.
9. Remove steering gearbox mounting brackets, then the steering gearbox together with mounting rubber.
10. Remove tie rod end from inner tie rod.
11. Remove dust cover from ball joint.
12. Remove bellows band and bellows clip, then pull bellows out toward tie rod.
13. Remove feed tubes from gear housing.
14. While moving rack slowly, drain fluid from gear housing.
15. Using a suitable chisel, unstake tab washer which fixes tie rod and rack.
16. Remove tie rod from rack.
17. Remove rack support plug locknut.
18. Using a suitable yoke plug socket, remove rack support plug.
19. Remove rack support spring, rack support and bushing from gearbox.
20. Remove end plug self-locking nut.
21. Detach dust seal.
22. Using suitable snap ring pliers, remove snap ring.
23. Using a soft hammer, remove pinion and valve assembly together with oil seal.
24. Turn rack stopper clockwise until end of circlip comes out of slot in gear housing.
25. When end of circlip comes out from notches hole of housing rack cylinder, turn rack stopper counter clockwise and remove circlip.
26. Remove rack stopper, rack bushing and rack from gear housing by moving it toward piston side.
27. Remove O-ring and oil seal from rack bushing.
28. Using drift tool No. 09517-21400, or equivalent, and a suitable hammer, drive out ball bearing.
29. Drive out needle bearing and oil seal.
30. Use bar tool and oil seal guide tool Nos. 0955-2100 and 09573-33100, or equivalents, to remove back washer and oil seal from gear housing.