Disassembly

NOTE: Overhaul of steering box should not be carried out during the warranty period.

WARNING: Wear safety glasses while removing and refitting circlips and retaining ring.

CAUTION: Absolute cleanliness is essential when overhauling power steering box.





1. With steering box removed from vehicle, remove drop arm using extractor tool No. LRT-57-012, or equivalent.
- Loosen drop arm securing nut, but do not remove before using extractor.
- Remove dirt excluder from output shaft.
2. Drain oil, remove blanking plugs and bleed screw.
- Hold steering box over suitable container, turn input shaft from lock to lock, until oil is drained.
- Refit bleed screw.





3. Rotate retainer ring (3) until one end is 12 mm from extractor hole.
- Using a drift through hole in cylinder, lift retaining ring from groove in cylinder bore.
4. Remove retainer ring, (3) using a screwdriver (4).
5. Turn input shaft (left lock on left hand drive, right lock on right hand drive) until piston pushes out cover (5).
- Turn input shaft fully in opposite direction, applying pressure to piston.
6. Remove set screw retaining rack pad adjuster.
7. Remove rack adjuster and pad.





8. Remove sector shaft adjuster locknut (8).
9. Remove four bolts from sector shaft cover(9).
10. Screw in sector shaft adjuster (10) until cover (9) is removed.

NOTE: Sealant is applied to hexagon socket to "tamperproof" sector shaft adjuster

11. Slide out sector shaft.
12. Remove piston, a bolt screwed into piston will assist removal.
13. Remove input shaft dirt excluder.





14. Remove worm adjuster locknut (15) using "C" wrench tool No. LRT-57-007, or equivalent.
15. Remove worm adjuster using wrench tool No. LRT-57-006, or equivalent.





16. Tap splined end of shaft (16) to free bearing.
17. Remove bearing cup and caged ball bearing assembly (17).
18. Remove valve and worm assembly (18).
19. Remove inner bearing cage, cup and shim washers (19).
- Retain shims for reassembly.

NOTE:
^ Should difficulty be experienced, warm casing and bearing assembly.
^ Cool bearing cup using a mandrel and tap steering box on a bench.





20. Remove circlip and seal (20) from sector shaft housing bore.

CAUTION:
^ Do not remove sector shaft bearings from casing.
^ Replacement parts are not available.
^ If sector shaft bearings are worn fit a new steering box.

21. Remove dirt excluder, circlip and seal (21) from input shaft housing bore.

CAUTION: The use of a seal puller is recommended to prevent damage to casing, and possible oil leaks.