Disassembly and Reassembly
Disassembly1. Secure the steering gear in a vice equipped with the protective jaw caps.
2. Remove the oil pipe.
3. Place the alignment marks on the left tie rod end to aid an installation.
4. Loosen the lock nut and remove the left tie rod end.
5. Remove the boot clips.
6. Remove the boot wires.
7. Remove the boots.
8. Remove the tie rods from the rack.
9. Remove the yoke plug locknut and yoke plug.
10. Remove the spring and support yoke.
11. Remove the pinion and control valve assembly snap ring.
12. Remove the oil seal.
13. Remove the two valve housing attaching bolts.
14. Remove the valve housing and the pinion and control valve assembly.
15. If present, remove the shim(s) from the steering gear housing.
16. Remove the O-ring.
17. Remove the lower pinion bearing from the steering gear housing.
18. Tap lightly with a rubber mallet to remove the pinion and control valve assembly from the valve housing.
19. Remove the four Teflon* seals from the pinion and control valve assembly.
20. Use the suitable tool to press the bearing out of the valve housing.
21. Use the Outer Box Torque Adapter to rotate the rack bushing until the hooked end of the retaining wire is aligned with the slot in the steering gear housing.
22. Rotate the bushing.
23. Remove the rack from the right side of the steering gear.
24. Remove the bushing from the rack.
25. Remove the O-ring.
26. Use the Rack Oil Seal Remover to remove the seal by bottoming it into the rack with a plastic hammer.
27. Use the impact Slide Hammer and the Rack Oil Seal Remover to pull the seal out of the rack.
28. Remove the mounting brackets and grommets.
Assembly
1. Install the grommets and mounting brackets.
Notice Ensure the lip spring of the seal-points toward the installation tool.
2. Use the Rack Oil Seal Replacer and install a new seal.
3. Install a new O-ring by using the Piston Seal Replacer and the Rack Piston Seal Sizer.
4. Place the Short Rack Seal Protector over the end of the rack to protect the bushing. Install the bushing on the rack.
5. Place the Rack Oil Seal Protector over the rack as shown. Install the rack, with the rack oil seal protector, into the steering gear housing. Remove the rack oil seal protector.
6. Use the Pinion Bearing Replacer to install the lower pinion bearing.
7. If the valve housing, steering gear housing, or pinion and control valve assembly have been replaced, perform the valve housing adjustment procedure outlined in this section. If none of these components have been replaced, install any shims that were removed.
8. Use the Seal Installation Set to install a new Teflon(R) pinion seals on the pinion and control valve assembly.
a. Install the first seal (the seal closest to the bearing) by sliding the Mandrel over the valve assembly to the first seal groove. Push the seal into the groove by using the Pusher.
b. Size the seal by sliding the large end of Sizer over the seal.
c. Before installing the second seal, place one Spacer, on the valve assembly as shown. Install and size the seal by using the Mandrel and the Pusher.
d. Before installing the third seal, place two Spacers, on the valve assembly.Make sure both spacers are positioned on the valve assembly as the one shown. Install and size the third seal.
e. To install the fourth seal, turn the second spacer around so the small ends of the spacers are facing each other on the valve assembly.
9. Insert the pinion and control valve assembly into the valve housing making sure that it seats properly.
10. Install a new O-ring.
11. Position the valve housing and the pinion and control valve assembly, then install the valve housing bolts.
Tighten the valve housing bolts to 15 - 19 ft. lbs. (21 - 26 Nm, 2.1 - 2.6 kg-m).
12. Use the Pinion Seal Replacer / Torque Adapter to install the bearing.
13. Use the Pinion Seal Replacer / Torque Adapter to install the seal.
14. Install the support yoke.
15. Install the spring.
16. Apply a sealant to the yoke plug threads. Install the yoke plug and tighten it to the specified torque.
Tightening torque:
14.5 ft. lbs. (19.6 Nm, 2 kg-m)
17. Loosen the support yoke.
18. Tighten the yoke plug with torque wrench to 43 inch lbs. (4.9 Nm, 50 kg-cm) three times, then return it 67.5 degrees.
19. Measure the pinion torque with the SST and spring scale.
Standard:
Center of rack ± 90°
6.9 - 11.3 inch lbs. (0.8 - 1.3 Nm, 8 - 13 kg-cm)
Scale reading: 800 - 1,300 kg (28.2 - 45.9 oz.)
20. If not within the specification, repeat steps 18 through 21.
21. Use the Yoke Locknut Wrench to install the locknut and tighten to 29 - 36 ft. lbs. (39 - 49 Nm, 4 - 5 kg-m).
22. Install the tie rods.
23. Align the washer with the rack groove, and then crimp the washer.
24. Install the boots.
25. Install the boot wires.
26. Install the boot clips.
27. Install the left tie rod end and lock nut.
28. Install the oil pipes.