Disassembly and Assembly
DISASSEMBLY1. 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.
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 0.079-0.098 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.
Fig. 2 Rack stroke L measurement:
Fig. 3 Rear housing cover installation:
Fig. 4 Lock plate installation:
Fig. 5 Tie-rod length L measurement:
Fig. 6 Rack stroke measurement:
Fig. 7 Boot clamp:
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, or equivalent, 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.
6. Set rack gear in neutral position. Rack stroke "L", Fig. 2, should be 2.58 inches.
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 0.04°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.
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.
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 tighten to specifications.
d. Clinch two places of lock plate at rack groove. To prevent scratching the boot, remove burrs from lock plate.
16. Refer to Fig. 5, when adjusting outer socket locknut length "L" to 6.43 inches.
17. Measure rack stroke, Fig. 6, stroke should be 2.58 inches.
18. Before installing boot, coat contact surfaces between boot and tie-rod with grease.
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 suitable 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.