Disassembly

Fig. 2 Exploded View Of Steering Gear Assembly:

1. Remove tie rod end from tie rod, Fig. 2.
2. Remove dust cover from ball joint.
3. Remove bellows band and clip, then pull bellows out toward tie rod.
4. Remove feed tube from gear housing.
5. While moving rack slowly, drain fluid from gear housing.
6. Remove end plug.
7. With pinion turned clockwise until rack is locked, remove the self-locking nut.
8. Unstake tab washer between tie rod and rack with chisel.
9. Remove tie rod from rack, taking care not to twist rack.
10. Remove yoke plug locking nut.
11. Using socket tool No. 09565-21100, or equivalent, remove yoke plug.
12. Remove rack support spring, yoke and bushing from gearbox.
13. Remove two valve body housing attaching bolts and valve body housing.
14. Turn rack stopper clockwise until end of circlip comes out of slot in gear housing.
15. When end of circlip comes out from notched hole of housing rack cylinder, turn rack stopper counterclockwise and remove circlip.
16. Remove rack stopper, rack bushing and rack from gear housing by moving it toward pinion side. When rack has been removed, be sure to replace housing side oil seal.
17. Remove O-ring from rack bushing.
18. Remove oil seal from rack bushing.
19. Remove valve body from valve body housing with a rubber hammer.
20. Use bearing removal tool No. 09565-21000, or equivalent, to remove oil seal and bearing from valve body housing.
21. Use bearing removal tool No. 09517-21400, or equivalent, to remove bearing from gear housing. Be careful not to damage pinion valve cylinder inside gear housing.
22. Use bearing removal tool No. 09517-21400, or equivalent, to remove needle bearing from gear housing.
23. Use special tool Nos. 09573-21200 and 09555-21000, or equivalents, to remove back washer and oil seal from gear housing. Be careful not to damage rack cylinder inside of gear housing.