Disassembly

DISASSEMBLY
RACK HOUSING ASSEMBLY

Disconnect the four pipes from gearbox.

Note: Remove the pipes E and F as a single unit being fixed at clamp plate.

Secure the gearbox removed from vehicle in vice using ST.
ST 32005190 STAND

Important: Secure the gearbox in a vise using ST as shown. Do not attempt to secure it without this ST.





Remove the tie-rod end and lock nut from gearbox.


Remove the small clip from boot using pliers, and then move the boot to tie-rod end side.









Using a flat tip screwdriver, remove the band from boot.









Extend the rack approximately 40 mm (1.57 inch) out. Unlock the lock washer on both side of tie-rod end using a flat tip screwdriver.

Important: Be careful not to scratch the rack surface as oil leaks may result.








Using the ST, loosen the lock nut.
ST 32005191 SPANNER





Tighten the adjusting screw until it no longer tightens.





Using a wrench [32 mm (1.26 inch) width across flats] or adjustable wrench, remove the tie-rod.





Loosen the adjusting screw, and then remove the spring and sleeve.
Remove the two bolts securing valve assembly.





Carefully draw out the input shaft, and then remove the valve assembly.





Using a sharp pointed pliers, rotate the rack stopper in direction of the arrow until end of the circlip comes out of stopper. Rotate the circlip in opposite direction and pull it out.








Pull the rack assembly from cylinder side, and draw out the rack bushing and rack stopper together with the rack assembly.

Important: Be careful not to contact the rack to inner wall of cylinder when drawing out. Any scratch on the cylinder inner wall will cause oil leakage.








Remove the rack bushing and rack stopper from rack assembly.
Remove the oil seal from rack.
Insert the ST from pinion housing side, and then remove the oil seal using a press
ST 32005053 REMOVER









CONTROL VALVE ASSEMBLY
Disconnect the four pipes from gearbox.

Note: Remove the pipes E and F as a single unit being fixed at clamp plate.

Secure the gearbox removed from the vehicle in vise using ST.
ST 32005190 STAND
Important: Secure the gearbox in a vise using ST as shown. Do not attempt to secure it without this ST.





Using the ST, loosen the lock nut.
ST 32005191 SPANNER





Tighten the adjusting screw until it no longer tightens.





Loosen the adjusting screw, and then remove the spring and sleeve.
Remove the two bolts securing valve assembly.





Carefully draw out the input shaft, and then remove the valve assembly.





Slide the dust cover out.








Using a press remove the pinion and valve assembly from valve housing.








Using the ST and press, remove the dust seal, oil seal and special bearing from valve housing.
ST 32005047 INSTALLER & REMOVER SEAL

Important:
^ Do not apply force to the end surface of valve housing.
^ Do not reuse the oil seal after removal.









Remove the snap ring using snap ring pliers.

Important: Be careful not to scratch the pinion and valve assembly.





Press out the bearing together with the back up washer using pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555 inch) and press.








Remove the oil seal.