Steering Rack End Removal/Installation

Steering Rack End Removal and Installation





Removal

NOTE: Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.

1. Remove the steering gearbox Steering Gearbox Removal/Installation.

2. Remove the heat shield (A).






3. Remove the tie-rod ends and the locknut from the rack end.

4. Remove the boot band (A), and discard them. Remove the tie-rod clip (B), and pull the boot (C) away from the end of the steering gearbox.






5. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) to a work bench as shown. Do not clamp the cylinder part of the gearbox housing in a vise.






6. Unbend the lock washer (A).






7. Hold the flat surface sections (A) of the steering rack (B) with one wrench, and unscrew both rack end (C) with another wrench. Be careful not to damage the rack shaft surface with the wrench.





8. Remove the lock washer (D) and the rubber stop (E).

Installation

1. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) to a workbench as shown. Do not clamp the cylinder part of the gearbox housing in the vise.






2. Install a new rubber stop (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 shaft.





3. Hold the flat surface sections of the steering rack with one wrench, and tighten both rack ends with another wrench. Be careful not to damage the rack surface with the wrench.

4. Bend the new lock washer (A) back against the flat spots (B) on the rack end joint housing.






5. Apply multipurpose grease to the circumference of the rack end joint housing (A).





6. Apply a light coat of silicone grease to the boot grooves (B) on the rack end.

NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.

7. Center the steering rack within its stroke.

8. Clean off 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.





9. After installing the boots, wipe the grease off the threaded section (D) of the rack end.

10. Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.






11. Close the ear portion (A) of the boot band (B) with commercially available boot band pliers, Oetiker 1098 or equivalent (C).





12. Slide the rack shaft right and left to be certain that the boots are not deformed or twisted.

13. Install the tie-rod end and the locknut to the rack end.

14. Install the heat shield (A), then tighten the bolts to the specified torque.






15. Install the steering gearbox.