Steering Rack

Steering Rack

Removal

1. Open engine compartment and fit paintwork protection covers.

2. Centralize steering wheel and remove ignition key.

3. Raise vehicle on a four-post ramp.

4. Place a drain pan under the steering rack





5. From below the vehicle, check that steering rack is centralized by aligning the centralizing notch on the dirt protection cover with the location hole in the pinion housing casting.





6. Remove nuts from LH and RH tie rod ends.





7. Release tie rod end taper-pin from steering arm.
- Fit special tool to tie rod end.
- Tighten tool bolt to release taper.
- Remove tool.
- Repeat procedure on opposite tie rod end.





8. Release steering column from pinion shaft.
- Remove clamp bolt.
- Move column upwards to release.





9. Disconnect electrical connector from steering rack transducer.





10. Remove insulation rubbers from hose secured to steering rack.
- Remove tie straps.
- Remove insulation rubbers.





11. Release retaining plate from pinion shaft cover, to access hoses.
- Remove bolt.
- Move retaining plate along hose.





12. Position drain pan under pinion-shaft housing and disconnect hoses.
- Allow fluid to drain.





13. Remove and discard O-ring seal from feed hose.





14. Remove and discard O-ring seal from return hose.

15. Fit blanking plugs to feed hose, return hose and pinion housing ports.

16. Remove drain pan and discard fluid.

NOTE: The steering rack mounting bushes are handed; they are marked accordingly and should be replaced as a pair.

17. Remove steering rack mounting bracket bushes.

NOTE: When removing steering rack, manoeuvre return pipe past the pinion housing to steering rack pipes.

18. Remove steering rack.

19. Using a tap (M 10 x 1.5 mm), clean the steering rack to crossbeam bolt hole threads.

Installation

1. Position steering rack to vehicle.

NOTE: When installing steering rack, manoeuvre return pipe past the pinion housing to steering rack pipes.

2. Fit steering rack mounting bracket bushes.

3. Unscrew tie rod end, taper pin nuts.
- Remove and discard protective covers from tie rod ends.

4. A new steering rack and pinion housing assembly is supplied with a dirt protection cover/centralizing cap fitted.

5. Remove blanking plugs from feed and return hoses and pinion housing ports of the new steering rack.





6. Connect return hose to pinion shaft housing.
- Apply clean PAS fluid to a new O-ring and fit to hose.
- Connect and fully seat hose.





7. Connect feed hose to pinion shaft housing.
- Apply clean PAS fluid to a new O-ring and fit to hose.
- Connect and fully seat hose.





8. Fit retaining plate to pinion housing.
- Align retaining plate and hoses.
- Fit and tighten bolt.

9. Clean any fluid spillage from steering rack and surrounding area.





10. Secure hose to steering rack.
- Fit insulation rubbers.
- Secure hose to steering rack with tie straps.





11. Connect tie rod ends.
- Locate tie rod end into steering arm.
- Fit and tighten nut.
- Repeat procedure to fit opposite tie rod end.

NOTE: Make sure steering wheel and wheels are in the straight ahead position before fitting steering column.





12. Fit steering column to pinion shaft.
- Move column downwards onto pinion shaft splines.
- Fit and tighten clamp bolt.





13. Connect electrical connector to steering rack transducer.

14. Fit a new fluid reservoir, refill with new power steering fluid and bleed air from the system.

15. Check and adjust front wheel alignment.