Disassembly and Assembly

Fig. 16 Exploded view of power steering gear.:

Disassembly

1. Remove tie rod end from tie rod, then the dust cover from ball joint, Fig. 16.
2. Remove air hose clamp, then the air hose, if equipped.
3. Remove bellows band, then the clip.
4. Pull bellows out toward tie rod.
5. Remove feed tube from gear housing, then while slowly moving rack, drain fluid from gear housing.
6. Remove end plug, then with pinion turned clockwise until rack is locked, remove self locking nut.
7. Unstake tab washer which attaches tie rod to rack using a suitable tool.
8. Remove tie rod from rack, then the rack support cover locking nut.

Fig. 17 Rack support cover removal.:

Fig. 18 Rack support component removal.:

9. Remove rack support cover using tool No. MB990607 or equivalent, Fig. 17, then the support spring, cushion rubber and rack support from gearbox, Fig. 18.

Fig. 19 Snap ring removal:

10. Remove snap ring, Fig. 19, then the pinion and valve assembly with oil seals, using a suitable drift.
11. Rotate rack stopper clockwise until end of circlip is removed from slot in gear housing, then turn rack stopper counterclockwise and remove circlip.
12. Push rack piston toward piston side, then remove rack stopper, rack bushing and rack from gear housing.
13. Remove O-ring and oil seal from rack bushing, then the ball bearing from gear using a suitable drift.
14. Remove rear washer and oil seal from gear housing, using a suitable tool, then the resin ring from the rack or pinion and valve assembly.

Assembly

1. Apply a suitable lubricant to resin ring, then insert into ring groove.
2. Work ring with fingers to reduce diameter, then apply a suitable lubricant to rack oil seal.

Fig. 20 Back-up washer and oil seal installation:

3. Install backup washer and oil seal using tool No. MB991097 & MB991098, until installation guide on top surface is flush with stepped portion of installation tool, Fig. 20.

Fig. 21 Needle bearing installation:

4. Apply a suitable lubricant to surface of needle bearing, then place inscribed side of bearing into tool No. MB991100 and insert it into gear housing until tool bottoms, Fig. 21.

Fig. 22 Pinion oil seal installation:

5. Apply a suitable lubricant to pinion oil seal, then install seal into housing using tool No. MB991100 until tool bottoms, Fig. 22.
6. Apply a suitable lubricant to ball bearing, then install using a suitable tool.

Fig. 23 Rack bushing oil seal installation:

7. Apply a suitable lubricant to rack bushing oil seal surface, then insert seal into rack bushing using tool Nos. MB990938-01 and MB990927-01, Fig. 23.
8. Insert rack bushing O-ring, then apply a suitable lubricant to rack teeth.
9. Cover rack with vinyl bag supplied with repair kit, apply a suitable lubricant to surface and slowly insert rack into gear housing.

Fig. 24 Vinyl tape application:

10. Apply a suitable lubricant to rack bushing and stopper, then wrap vinyl tape around end, Fig. 24, and install rack bushing and stopper.
11. Push rack stopper until circlip groove is aligned with notched hole of housing, then insert circlip while turning rack stopper.
12. Apply a suitable lubricant to pinion valve assembly, then install gear housing assembly.
13. Wrap vinyl tape around serrated section of pinion valve assembly, then apply a suitable lubricant and install seal using a suitable tool.
14. Install snap ring into groove, then the new tab washer and tie rod. Caulk tab washer end at two points to the tie rod.
15. Rotate pinion fully clockwise, then tighten new self-locking nut.
16. Apply a suitable sealant to threaded section of end plug, then torque to 36-51 ft. lbs.

Fig. 18 Rack support component removal.:

17. Stake end plug at two points using a suitable tool, then install rack support, rack support spring and cover as shown, Fig. 18. Apply a suitable lubricant to threaded section of rack support cover prior to installation.
18. Place rack at center position, then torque rack support cover to 14-18 ft. lbs. Loosen cover approximately 30-60 degrees, torque to 36-51 ft. lbs.
19. Torque feed tube nuts to 9-13 ft. lbs., then install mount rubber using a suitable adhesive.
20. Apply a suitable lubricant to bellows fitting position of tie rod, then install new bellows band. Install bellows.
21. Fill inside of dust cover with a suitable lubricant, then place dust cover into position with clip ring attached to groove at tie rod end.

Fig. 25 Tie rod end installation:

22. Install tie rods until free length of left and right rods are 6.69-6.74 inch, Fig. 25.