Disassembly and Assembly

Fig. 1 Exploded View Of Power Steering Gear (PR26SC):

DISASSEMBLY

1. Before disassembling, proceed as follows:
a. Disconnect gear housing tube and drain fluid.
b. Measure pinion rotating torque, then note position for reference.
c. Use a soft-jawed vise when holding steering gear housing. Handle gear housing carefully.
2. Remove pinion gear, ensure not to damage pinion gear when removing seal ring, Fig. 1.
3. Remove tie-rod outer sockets and boots.
4. Loosen tie-rod inner socket by prying up staked portion, then remove socket.
5. Remove retainer and pinion assembly.
6. Drill staked area of gear housing end of .079-.098 inch diameter, until staking is eliminated.
7. Using suitable tool, remove end cover assembly.
8. Draw out rack assembly, then remove rack seal ring.
9. Using a heat gun, heat rack seal to approximately 104°F, then remove rack seal ring. Ensure not to damage rack.
10. Using a tape wrapped socket and extension bar, remove center bushing and rack oil seal. Do not scratch inner surfaces of pinion housing.

ASSEMBLY

1. Using a heat gun, heat rack seal ring (made of Teflon) to approximately 104°F, then install onto rack.
2. Using rack seal ring reformer tool No. KV48104400, compress periphery of rack seal ring to position, then secure it on rack. Always insert tool from rack gear side.
3. Insert rack oil seal as follows:
a. Place plastic film into oil seal to prevent damage by rack teeth.
b. Always remove plastic film after oil seal is positioned properly.
c. Ensure lips of oil seal face each other.
4. Install center bushing and oil seal with rack assembly, then tighten end cover assembly with suitable tool.
5. Fasten end cover assembly to gear housing by staking.

Fig. 2 Measuring Rack Stroke L:

6. Set rack gear in neutral position. Rack stroke ``L'' should be 2.80 inch, Fig. 2.
7. Apply grease to oil seal lip, then install to pinion housing of gear housing. Ensure oil seal lip faces up.
8. Install pinion bearing adjusting shim(s). Replace shims with new ones when disassembling using the same number of shim(s).
9. Using a heat gun, heat pinion seal ring to approximately 104°F before installing it onto pinion gear assembly. Ensure pinion seal ring is properly settled in valve groove.
10. Apply grease to needle bearing roller and oil seal lip before installing pinion assembly in gear housing.
11. Install pinion assembly to pinion housing of gear housing. Ensure not to damage pinion oil seal.
12. Apply grease to rear oil seal lip before installing rear housing.

Fig. 3 Positioning Rear Housing Cover.:

13. Install rear cover cap so protrusion of rear housing cover is positioned as shown in Fig. 3. when rack is centralized. Ensure not to damage worn ring and oil seal.
14. Install diaphragm spring at retainer as follows:
a. Always install retainer, spring washer and diaphragm spring in that order.
b. Ensure convex end (painted white) of diaphragm spring faces outward when installing.
c. Temporarily install retainer spring and adjusting screw.

Fig. 4 Lock Plate Installation.:

15. Install lock plate as follows:
a. Attach lock plate (2) to side rod inner socket (1), Fig. 4.
b. Apply suitable locking sealant to inner socket threads (3).
c. Screw inner socket into rack (4), then torque to specifications.
d. Clinch two places of lock plate at rack groove, To prevent scratching the boot, remove burrs from lock plate.

Fig. 5 Measuring Tie-rod Length L:

16. Tighten outer socket locknut length L, to 5.65 inch on M30 models or 6.95 on G20 models, Fig. 5.

Fig. 6 Measuring Rack Stroke:

17. Measure rack stroke ``L,''to 2.80 inch on M30 models or 2.736 on G20 models, Fig. 6.
18. Before installing boot, coat contact surfaces between boot and tie-rod with grease.

Fig. 7 Twist Boot Clamp.:

19. Install boots clamps as follows:
a. Wrap boot clamp around boot groove twice.
b. Tighten clamp by twisting rings at both ends 4-4 1/2 turns with screwdriver while pulling with a force of approximately 22 lbs.
c. Twist boot clamp as shown in Fig. 7.
d. After twisting boot clamp, bend twisted portion inward so it does not contact boot.