Disassembly

NOTE: When using a vise, do not overtighten it.

Second Of Three:

1. Using the 09612-00012 SST, secure the gear assembly in a vise.
2. Remove the two turn pressure tubes by performing the following.
a. Using the 09633-00020 SST, remove the tube.





b. Remove the two O-rings from the tube.

3. Remove the right and left hand tie rod ends and lock nuts after performing the following.





a. Place matchmarks on the tie rod end and rack end.
b. Loosen the lock nut.





4. Remove the right and left hand clips, rack boots and, using a screwdriver, loosen the clamps.

NOTE:
^ Be careful not to damage the boot.
^ Mark the right and left hand boots.

5. Remove the right and left rack ends and claw washers by performing the following.





a. Using a screwdriver and hammer, unstake the washer.

NOTE: Avoid any impact to the steering rack.





b. Using a (24 mm) spanner to hold the steering rack steady, and using the 09922-1 0010 Special Service Tool (SST), remove the rack end.

NOTE:
^ Use SST 09922-10010 in the direction shown in the illustration. ^ Mark the right and left hand rack ends.
c. Remove the washer from the rack end.





6. Using the 09922-1 0010 SST, remove the rack guide spring cap lock nut.

NOTE: Use the 09922-10010 SST in the direction shown in the illustration.

7. Remove the rack guide spring cap, rack guide spring, rack guide and the rack guide seat by performing the following.





a. Using the 09631-10021 SST, remove the cap.
b. Remove the seat from the guide.
8. Remove the rack housing cap.





9. Using the 09616-00010 SST to stop the control valve shaft rotating, remove the self-locking nut.

10. Remove the dust cover.
11. Remove the control valve housing with the control valve assembly.





a. Place matchmarks on the valve housing and rack housing.
b. Remove the two bolts.
c. Remove the gasket from the rack housing.
12. Remove the control valve assembly , performing the following.
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
b. Press out the valve assembly with the oil seal.





NOTE:
^ Place a shop rag between the valve housing and the blocks.
^ Be careful not to drop the valve assembly.
^ Be careful not to damage the oil seal lip.

13. Remove the oil seal from the control valve assembly.
14. Remove the rack housing No.2 bracket and the grommet.





a. Place matchmarks on the bracket and rack housing.





b. Using a screwdriver, pry the clamp of the bracket.
c. Remove the grommet from the bracket.





15. Remove the cylinder end stopper by following these procedures.
a. Using the 09631 - 10021 SST, turn the stopper clockwise until the wire end is visible through the service hole.
b. Using the 09631 -10021 SST, turn the stopper counterclockwise, and remove the wire.
16. Remove the steering rack and bushing, performing the following.





a. Using a brass bar and hammer, tap out the rack with the bushing.
b. Remove the bushing from the rack.
c. Remove the O-ring from the bushing.





17. Using the 09950-60010 (09951-00290), 09950-70010 (09951-07360) SST, press out and remove the oil seal.