Part 2
Steering Gearbox Overhaul (Continued)37. Apply power steering fluid to the surface of the sleeve seal ring guide. Slip two new seal rings (A) over the ring guide from the smaller diameter end, and expand them. Install only two rings at a time from each end of the pinion shaft sleeve (B).
Note these items when installing the seal ring:
^ Do not over-expand the seal ring. Install the resin seal rings with care so as not to damage them. After installation, make sure you contract the seal rings using the sizing tool.
^ There are two types of sleeve seal rings; black and brown. Do not mix the different types of rings as they are not compatible.
38. Align the ring guide with each groove in the sleeve, and slide a sleeve seal ring into each groove. After installation, compress the seal rings with your fingers temporarily.
39. Apply power steering fluid to the seal rings on the sleeve, and to the entire inside surface of the sleeve seal ring sizing tool, then slowly insert the sleeve into the sizing tool.
40. Move the sleeve back and forth several times to make the seal rings fit snugly in the sleeve. Make sure the seal rings are not twisted.
41. Apply power steering fluid to the surface of the pinion shaft (A). Slide the sleeve (B) onto the pinion shaft by aligning the locating pin (C) on the inside of the sleeve with the cutout (D) in the shaft. Then install the new snap ring (E) securely in the pinion shaft groove. Be careful not to damage the valve seal ring when inserting the sleeve.
42. Apply power steering fluid to the seal ring lip of the new valve oil seal (A), then install the seal in the valve housing (B) using a hydraulic press, driver, and the attachment. Install the seal with its grooved side facing the tool.
43. Press the roller bearing (C) into the valve housing with a hydraulic press, driver, and the attachment.
44. Apply vinyl tape (A) to the pinion shaft, then coat the vinyl tape with power steering fluid.
45. Insert the pinion shaft into the valve housing (B). Be careful not to damage the valve seal rings (C) and valve oil seal sealing lip (D).
46. Remove the vinyl tape from the pinion shaft, then remove any residue from the tape adhesive.
47. Press the pinion shaft/sleeve into the valve housing with a hydraulic press. Check that the pinion shaft/sleeve turns smoothly by hand after installing it.
48. Coat the piston seal ring guide with power steering fluid, then slide it onto the rack, big end first.
49. Position the new O-ring (A) and new piston seal ring (B) on the piston seal ring guide, then slide them down toward the big end of the tool.
Note these items during reassembly:
^ Do not over expand the resin seal rings. Install the resin seal rings with care so as not to damage them. After installation, make sure you contract the seal ring using the sizing tool.
^ Replace piston's O-ring and seal ring as a set.
50. Pull the O-ring off into the piston groove, then pull the piston seal ring off into the piston groove on top of the O-ring.
51. Coat the piston seal ring (A) and the inside of the piston seal ring sizing with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.
52. Move the piston seal ring sizing tool back and forth several times to make the piston seal ring fit snugly in the piston.
53. Coat the sliding surface of the cylinder end seal slider (A) and new cylinder end seal (B) with power steering fluid. Place the seal on the cylinder end seal slider with its grooved side (C) facing opposite the cylinder end seal slider.
54. Coat the surface of the steering rack (A) with power steering fluid.
55. Install the cylinder end seal (B) onto the steering rack with its grooved side (C) toward the piston (D).
56. Separate the cylinder end seal from the cylinder end seal slider, then remove the cylinder end seal slider.
57. Install the new backup ring (A) on the steering rack, then place the backup ring and cylinder end seal (B) against the piston (C).
58. Apply Multi-purpose grease to the steering rack teeth, then insert the steering rack into the gearbox housing. Be careful not to damage the inner surface of the cylinder wall with the rack edges.
59. Insert an appropriate size deep socket wrench (A) onto the steering rack as shown.
60. Install the cylinder end seal (B) into the bottom of the cylinder by pressing on the tool with a press. Do not push on the tool with excessive force as it may damage the cylinder end seal.
61. Remove the tool, and center the steering rack.
62. Coat the sliding surface of the cylinder end seal slider (A) and new cylinder end seal (B) with power steering fluid. Place the seal on the cylinder end seal slider with its grooved side (C) facing opposite the cylinder end seal slider.
63. Coat the inside surface of the cylinder end seal slider and steering rack with power steering fluid, then install the cylinder end seal (A) onto the steering rack with its grooved side toward the cylinder.
64. Separate the cylinder end seal from the cylinder end seal slider, then remove the cylinder end seal slider.
65. Push in the cylinder end seal with your finger. Be careful not to damage the face of the seal with the threads and burrs at the staked position of the cylinder housing.
66. Hold the gearbox housing using a C-clamp (commercially available) (A) and wooden blocks (B). Do not clamp the cylinder part of the gearbox housing in the vise.
67. Coat the inside surface of the cylinder end (A) with power steering fluid, then install the cylinder end by screwing it into the cylinder (B). Tighten the cylinder end to the specified torque.
68. Stake the point of the cylinder shown (opposite from where the stake was removed during disassembly).
69. Coat the new O-ring (A) with Multi-purpose grease, and carefully fit it on the valve housing.
70. Apply Multi-purpose grease to the needle bearing (B) in the gearbox housing, then install the valve body unit (C) by engaging the gears. Note the valve body unit installation position (direction of the line connections).
71. Tighten the flange bolts (D) to the specified torque.
72. Install the cylinder lines.
Note these items during reassembly:
^ Thoroughly clean the joints of the cylinder lines. The joints must be free of foreign material.
^ Install the cylinder lines by tightening the flare nuts by hand first, then tighten the flare nuts to the specified torque.
73. Apply Multi-purpose grease to the sliding surface and circumference of the rack guide (A), and install it onto the gearbox housing.
74. Install the spring (B) and rack guide screw (C).
75. Tighten the rack guide screw, and loosely install the locknut (D).
76. Check that the rack moves smoothly by sliding it right and left.
77. Install a new stop rubber (A) and a new lock washer (B). Align the lock washer tabs (C) with the slots (D) on the rack end (E) while holding the lock washer in place. Repeat this step for the other side of the rack.
78. Hold the flat surface sections of the steering rack with a wrench, and tighten both rack ends. Be careful not to damage the rack surface with the wrench.
79. Bend the lock washer (A) back against the flat spots on the rack end joint housing.
80. Apply Multi-purpose grease to the circumference of the rack end joint housing (A).
81. Apply a light coat of silicone grease to the boot grooves (B) on the rack ends.
82. Center the steering rack within its stroke.
83. Clean any grease or contamination from the boot installation grooves (A) around on the gearbox housing. Install the boots (B) on the rack ends with the tie-rod clips (C), and fit the boot end in the installation grooves in the housing properly.
84. After installing the boots, wipe the grease off the threaded section (D) of the rack end.
85. Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.
86. Close the ear portion (A) of the band (B) with commercially available pincers, Oetiker 1098 or equivalent (C).
87. Slide the rack right and left to be certain that the boots are not deformed or twisted.
88. Reinstall the steering gearbox.
89. Adjust the rack guide screw. After adjusting, check that the rack moves smoothly by sliding it right and left.