Disassemble
DISMANTLERemoving Pitman Arm:
1. Remove the steering box from the vehicle, and withdraw the pitman arm.
Steering Gear End Cover Retainer:
2. Rotate the retainer ring, as necessary, until one end is approximately 12 mm (0.500 in) from the extractor hole.
3. Lift the cover retaining ring from the groove in the cylinder.bore, using a suitable pointed drift applied through the hole provided in the cylinder wall.
4. Complete the removal of the retainer ring, using a screwdriver.
5. Turn on left lock until the piston pushes out the end cover.
Steering Gear:
6. Loosen the set screw retaining the rack pad adjuster.
7. Remove the rack pad adjuster.
8. Remove the sector shaft adjuster locknut.
9. Remove the sector shaft cover fasteners.
10. Screw in the sector shaft adjuster until the cover is removed.
11. Slide out the sector shaft.
12. Withdraw the piston using a suitable bolt screwed into the tapped hole in the piston.
C Wrench:
13. Remove the worm adjuster locknut using C Wrench, LST120.
14. Remove the worm adjuster using wrench LST119.
15. Tap the splined end of the shaft to free the bearing.
Bearings:
16. Withdraw the bearing cup and caged ball bearing assembly.
17. Withdraw the valve and worm assembly.
18. Withdraw the inner bearing ball race and shims.
19. Retain the shims for reassembly
Steering Box Seals
Steering Gear Seals:
20. Remove the circlip and seals from the sector shaft housing bore.
NOTE: Do not remove the sector bushes from the casing. Replacement parts are not available.
21. Remove the circlip and seals from the input shaft housing bore.
Inspecting
Rubber Seals:
22. Discard all rubber seals and provide replacements.
NOTE: A rubber seal is fitted behind the plastic ring on the rack piston. Discard the seal and also the plastic ring and provide replacements.
Steering Box Casing
Steering Gear Case:
23. Examine the piston bore for traces of scoring and wear.
24. Examine the inlet tube thread for damage. If repair is necessary this can be undertaken by using a suitable tap.
25. Examine the feed tube for signs of cracking.
Sector Shaft Assembly
Sector Shaft:
26. Check that there is no side play on the rollers.
27. If excessive side play on the roller does exist fit a new sector shaft.
28. Check the condition of the adjuster screw threads.
29. Examine the bearing areas on the shaft for excessive wear.
30. Examine the gear teeth for uneven or excessive wear.
Sector Shaft Cover Assembly
31. The cover, bush and seat are supplied as a complete assembly for replacement purposes.
Sector Shaft Adjuster Locknut
32. The locknut functions also as a fluid seal, a new nut be fitted at overhaul.
Valve And Worm Assembly
Valve Seals:
33. Examine the valve rings which must be free from cuts, scratches and grooves. The valve rings should be a loose fit in the valve grooves.
34. Remove the damaged rings ensuring that no damage is done to the seal grooves.
35. If required, fit replacement rings using the ring expander 606602. Warm the rings and expander tool to aid assembly, using hot water for this purpose. Fit the rings to the expander, slide the expander over the valve and worm assembly, in turn fit the rings to their respective grooves. Remove the expander, slide the valve and worm assembly into the ring compressor 606603 and allow the rings to cool.
NOTE: The expander will not pass over rings already fitted. The rings must be discarded to allow access and then new rings must be fitted.
Valve/Worm Assembly:
36. Examine the bearing areas for wear. The areas must be smooth and not indented.
37. Examine the worm track which must be smooth and not indented.
38. Check for wear on the torsion bar assembly pins; no free movement should exist between the input shaft and the worm.
NOTE: Any sign of wear makes it essential that a new valve and worm assembly is fitted.
Ball Bearing And Cage Assemblies
Bearings:
39. Examine the ball races and cups for wear and general condition.
40. If the ball cage has worn against the bearing cup, fit replacements.
41. Bearing balls must be retained by the cage.
42. Bearings and cage repair are carried out by the complete replacement of the bearings and cage assembly.
43. To remove the inner bearing cup and shim washers, jar the steering box on the work bench, or use a suitable extractor.
NOTE: Should difficulty be experienced at this stage, warm the casing and the bearing assembly. Cool the bearing cup using a suitable mandrel and jar the steering box on the bench.
Rack Thrust Pad And Adjuster
Rack Thrust Pad:
44. Examine the thrust pad for scores.
45. Examine the adjuster for wear in the pad seat.
46. Examine the nylon pad for distortion and adjuster set screw assembly for wear.
Rack And Piston
Rack:
47. Examine for excessive wear on the rack teeth.
48. Ensure the thrust pad bearing surface is free from scores and wear.
49. Ensure that the piston outer diameters are free from burrs and damage.
50. Examine the seal and ring groove for scores and damage.
51. Fit a new rubber ring to the piston. Warm the white nylon seal and fit this to the piston.
52. Slide the piston assembly into the cylinder with the rack tube outwards. Allow to cool.