Disassembly

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





1. Secure power steering gear assembly in vise. Using Special Service Tool (SST) 09612 - 00012 or equivalent, secure the power steering steering gear assembly in a vise.
2. Remove two turn pressure tubes, as follows:
a. Remove the union bolt and the two gaskets.





b. Using SST 09633 - 00020 or equivalent, remove the tube.
c. Remove the two union seats from the rack housing.





3. Remove right and left tie rod ends and lock nuts. Place matchmarks on the tie rod end and rack end, and loosen the lock nut.
4. Remove right and left clips, rack boots and clamps.

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

5. Remove right and left rack ends and claw washers.





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

NOTICE: Avoid any impact to the steering rack.





b. Using a (22 mm) spanner to hold the steering rack and, using SST 09922 - 10010 or equivalent, remove the rack end.

NOTICE:
^ Use SST 09922 - 10010 or equivalent, in the direction shown in the illustration.
^ Mark the right and left rack ends.





6. Remove rack guide spring cap lock nut. Using SST 09922 - 10010 or equivalent, remove the nut.

NOTICE: Use SST 09922 - 10010 or equivalent in the direction shown in the illustration.

7. Remove rack guide spring cap, rack guide spring, rack guide and rack guide seat, as follows:
a. Using a (24 mm) hexagon wrench, remove the cap.
b. Remove the seat from the guide.
8. Remove rack housing cap.





9. Remove self-locking nut, bearing and spacer. Using SST 09616 - 00010 or equivalent, to stop the control valve shaft rotating, remove the nut.
10. Remove dust cover.
11. Remove control valve housing with control valve assembly, as follows:





a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
b. Using a (6 mm) hexagon wrench, remove the two bolts.
c. Remove the O-ring from the housing.





12. Remove control valve assembly. Using a plastic hammer, tap out the control valve assembly.

NOTICE: Be careful not to damage the oil seal lip.

13. Remove cylinder end stopper and spacer. Using snap ring pliers, remove the snap ring from the rack housing.
14. Remove steering rack and oil seal, as follows:





a. Using an extension bar or brass bar and a press, press out the rack with the oil seal.

NOTE: Take care not to drop the rack.

b. Remove the oil seal from the rack.





15. Remove oil seal. Using SST 09950 - 60010 (09951 - 00280), 09950 - 70010 (09951 - 07200) or equivalents, press out and remove the oil seal.