Disassembly

Before disassembly, note rack starting force and pinion preload torque in straight ahead position for reference at reassembly.
1. Wrap a shop towel around center portion of steering, gear, then mount gear in a soft-jawed vise.
2. Cut nylon bellows band, then remove bellows from left tie rod.
3. Unstake left tie rod end nut using a chisel, then remove tie rod from rack assembly.

Fig. 5 Exploded View Of Manual Steering Gear:

4. Remove yoke plug locknut, Fig. 5; then, using tool No. 09565-21100, or equivalent, remove yoke plug.
5. Remove yoke spring, cushion rubber and support yoke from gearbox.
6. Remove and discard oil seal.
7. Remove snap ring, then the pinion and bearing assembly.
8. Remove pinion bearing retainer snap ring; then, using tool No. 09565-21000, or equivalent, and a suitable press, press bearing from pinion.
9. Cut bellows band, then remove bellows from right tie rod.
10. Unstake right tie rod end nut, then move rack fully toward housing. Carefully position toothed portion of rack in a suitable vise and remove tie rod.

Fig. 3 Rack Removal From Gear Housing:

11. Remove rack from left side of gear housing to prevent damage to bushing, Fig. 3.