Disassembly

CAUTION:
- Mount the gear box in a soft jawed vise.
- Do not tighten the vise on the gear housing, Use the mounting section of the rack to secure it in the vise.





PROCEDURE
After removing the gear box, disassemble and remove the gear box components in the following order:







1. The outer tie rod end from the inner tie rod.







2. Dust cover from the ball joint.







3. The bellows band.






4. The bellows clip.
5. Pull the bellows out toward the tie rod.

NOTE: Check for rust on the rack when the bellows are replaced.

6. Feed tube from the gear housing.
7. While moving the rack slowly, drain the fluid from the gear housing.
8. Remove the end plug.
9. With the pinion turned clockwise until the rack is locked, remove the self-locking nut.







10. Unstake the tab washer between the tie rod and rack with a chisel.








11. Remove the inner tie rod from the rack.


NOTE: Remove the tie rod from the rack, taking care not to twist the rack.








12. Remove the yoke plug locking nut.








13. Using the Special Service Tool (SST), remove the yoke plug.







14. Remove the rack support spring, rack support yoke and bushing from the gear box.







15. Remove the valve body housing by loosening the two bolts.








16. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the gear housing.







17. When the end of the circlip comes out from the notched hole of the housing rack cylinder, turn the rack stopper counterclockwise and remove the circlip.







18. Remove the rack stopper, rack bushing and rack from the gear housing by moving it toward the pinion side.

NOTE: When the rack has been removed, be sure to replace the housing side oil seal.







19. Remove the O-ring from the rack bushing.







20. Remove the oil seal from the rack bushing.







21. Remove the valve body from valve body housing with a soft hammer.







22. Use the (SST) to remove the oil seal and ball bearing from the valve body housing.







23. Use the (SST) to remove the ball bearing from the gear housing.

NOTE: Be careful not to damage the pinion valve cylinder inside of the gear housing.







24. Use the special tool (09517-21400) to remove the needle bearing from the gear housing.






25. Use the special tools to remove the oil seal from the gear housing.


NOTE: Be careful not to damage the rack cylinder inside of the gear housing.