Front

1. Remove two valve body unit to gearbox attaching bolts.
2. Remove O-rings and port orifices from gearbox.
3. On models with 2WS, loosen rack screw locknut and remove rack guide screw.
4. On models with 4WS, loosen rack screw locknut and remove rack guide screw/sub steering angle sensor assembly.
5. Remove spring and rack guide from gear housing.
6. On models with 4WS, remove rack guide screw, O-ring and locknut from sub steering angle sensor.
7. Carefully clamp gearbox into vise with soft jaws.
8. Remove tie rod assembly, then the boot bands and tube clamps.
9. Pull dust seals away from ends of gearbox.
10. Hold steering rack with wrench and unscrew rack end, then remove dust cover.

Fig. 17 Exploded View Of Front Steering Gear:

11. Remove four gear housing cap to gear housing attaching bolts, Fig. 17.
12. Remove steering pinion seal from gear housing cap.
13. Push right end of rack back into cylinder housing so smooth surface that rides against seal will not be damaged.
14. Check pinion lower bearing for play. If there is no play and grease is satisfactory, proceed to next step. If bearing is noisy or has excessive play, proceed as follows:
a. Remove snap ring from pinion assembly.
b. Using suitable bearing puller, remove bearing from pinion assembly.
c. Press new bearing onto pinion assembly using a suitable press.
d. Install snap ring onto pinion assembly.
15. Remove four bolts from end of cylinder assembly.
16. Remove O-ring back-up ring, steering rack bushing A, cylinder spring and cylinder end seal from cylinder housing.
17. Remove cylinder, seal retainer, cylinder cap, steering rack and retainer washer from gear housing.

Fig. 18 Circlip Into Pinion Holder Installation:

18. Check pinion holder for free movement. If movement is satisfactory, proceed to next step. If there is excessive play or movement is rough, proceed as follows:
a. Remove circlip from pinion holder.
b. Remove pinion holder from gear housing.
c. Check needle roller bearings in pinion holder and gear housing for damage. If bearings are satisfactory, repack with grease. If bearing are worn or damaged, replace as a set.
d. Check lower ball bearing for damage, if bearing is satisfactory, proceed to next numerical step. If lower ball bearing is damaged, remove bearing from gear housing.
e. Using driver tool No. 07749-0010000 and attachment tool No. 07746-0010300, or equivalents, drive new lower bearing into gear housing.
f. Install pinion holder in gear housing.
g. Install circlip into pinion holder with its tapered side facing outward. Circlip ends must be aligned with flat area, Fig. 18.
19. Remove cylinder and seal retainer from steering rack.
20. Remove O-ring, snap ring and cylinder cap from seal retainer.
21. Remove O-rings from cylinder cap, then the bushing stopper ring from seal retainer.
22. Remove cylinder end seal and rack bushing B from steering rack.
23. Carefully pry piston seal ring and O-ring off of rack.