Inner

Tie Rods, Bellows Disassembly

1. Mount gear assembly in Bench Mounted Holding Fixture T57L-500-B or equivalent.

NOTE: Drill out mounting holes in holding fixture with a 9/16-drill to allow the gear assembly mounting bolts to fit.

2. Remove tie rod ends.

3. Remove four clamps retaining bellows to gear housing and tie rods. Discard clamps if damaged or excessively corroded.

4. Remove bellows along with breather tube.

CAUTION: Use care not to damage bellows.

NOTE: For units equipped with rivets in place of the coiled pins, perform Steps 6 and 7.






5. Using Locknut Pin Remover D81P-3504-N or equivalent, remove coiled lock pins from inner tie rod ball joints.







6. With a sharp chisel, gently tap around rivet head so it lifts away from ball joint. Use caution so the center pin is not sheared off.






7. Use sid-cutters to pry out drive pin.

8. Position rack so that several rack teeth are exposed. Hold rack with an adjustable wrench or end teeth only, while loosening ball joint nuts with Nut Wrench T74P-3504-U or equivalent.

Assembly






1. Expose several rack teeth and hold rack with adjustable wrench.

2. Tighten each ball joint assembly separately to 75-88 N.m (55-65 lb-ft) using Nut Wrench T74P-3504-U or equivalent.






3. Install new coiled pins in tie rod ball housing by tapping lightly with a small hammer.

4. Thoroughly clean rack and housing bore of any foreign material. Any abrasive material is extremely harmful to high-pressure oil seals.

NOTE: Replenish any grease that may have been removed from rack teeth with Steering Gear Grease C3AZ-19578-A (ESW-M1C87-A) or equivalent.

5. Apply Steering Gear Grease C3AZ-19578-A (ESW-M 1 C87-A) or equivalent to groove in rods where bellows clamp to tie rod. This allows for toe-in adjustment without twisting bellows.






6. Install bellows and breather tube. Ensure breather tube is positioned as shown.







7. Install clamps and position screw axis as shown. Tighten to 2.3-3.4 N.m (20-30 lb-in).

8. Install new clamps retaining bellows to tie rods.

9. Apply Disc Brake Caliper Slide Grease D7AZ- 19590-A (ESA-M1C172-A) or equivalent to tie rod threads.

10. Install tie rod outer ends.