Diassembly, Inspection and Reassembly

Disassembly

Fig. 39 Power Steering Gear:

1. Remove tie rod end from tie rod, then dust cover from ball joint, Fig. 39.
2. Remove bellows band, then the retaining clip.
3. Pull bellows out toward tie rod. Check for rust on rack when bellows are replaced.
4. Remove feed tube from gear housing, then while slowly moving rack, drain fluid from gear housing.
5. Remove end plug, then with piston turned clockwise until rack is locked, remove self locking nut.
6. Chisel tab washer of of rack, then remove tie rod from rack. Use care to avoid twisting tie rod when removing from rack.
7. Remove rack support cover locking nut, then using yoke plug socket 09565-21100 or equivalent, remove rack support cover.
8. Remove rack support spring, rack support and bushing from gearbox.
9. Remove valve body housing attaching bolts.
10. Rotate rack stopper clockwise, until end circlip is removed from slot in gear housing, then turn rack counterclockwise and remove circlip.
11. Remove O-ring and oil seal from rack bushing, then the oil seal from rack bushing.
12. Remove valve body from housing using a soft hammer.
13. Using pinion bearing remover 09565-21000 or equivalent, remove oil seal and ball bearing from valve body housing.
14. Remove ball bearing from gear housing, using a suitable drift. Ensure not to damage the pinion valve cylinder inside of gear housing.
15. Remove needle bearing from gear housing.
16. Using an oil seal guide 09573-21200 and bar 09555-21000 or equivalent, remove back washer and oil seal from gear housing.

Inspection

1. Check rack for excessive wear or damaged tooth surface.
2. Inspect all oil seal contact surfaces for damage.
3. Check bearing for seizure, abnormal noise and excessive play.
4. Inspect dust cover for cracking or other damage.

Assembly

1. Apply a suitable oil to entire surface of oil seal for rack.
2. Using a bearing installer tool No. 09432-21600 or equivalent, install back-up washer and oil seal in gear housing.
3. Apply suitable lubricant to surface of needle bearing. Place inscribed side of bearing in the bearing installer tool No. 09432-21600 or equivalent and insert it into gear housing until tool bottoms. Note direction of needle bearing.
4. Apply suitable lubricant to ball bearing, then install bearing, using a valve stem oil seal installer tool No. 09222-21100 or equivalent. Ensure to use a new ball bearing.
5. Apply lubricant to rack bushing oil seal surface, then insert seal into rack bushing using countershaft bearing installer tool No. 09434-14200 or equivalent.
6. Insert rack bushing O-ring, then apply a suitable lubricant to rack teeth. Do not plug vent hole in rack with grease.
7. Insert rack into gear housing, then install rack bushing and rack stopper.
8. Push rack stopper until circlip groove is aligned with notched hole in housing, then insert circlip while turning rack stopper, Ensure circlip end is not visible through notched hole of rack housing.
9. Using bearing installer, install oil seal and ball bearing to valve body.
10. Apply suitable lubricant to pinion valve assembly, then install to gear housing.
11. Using a countershaft bearing installer or equivalent, install the seal to valve body housing.
12. Install valve body assembly with the seal ring to gearbox, then the new tab washer and tie rod. Caulk tab washer end at two points to the tie rod.
13. Rotate pinion fully clockwise, then tighten new self-locking nut.
14. Apply suitable sealant to threaded section of end plug, then torque to 36-51 ft. lbs.

Fig. 40 Rack Support:

15. Stake end plug at two points using a suitable punch, then install bushing, rack support, spring, and support cover as shown, Fig. 40. Apply suitable lubricant to threaded section of rack support prior to installation.
16. Place rack at center position, then torque rack support cover to 8 ft. lbs. Loosen cover approximately 30-60°, then torque locking nut to 36-51 ft. lbs.
17. Torque feed tube nut to 9-13 ft. lbs; then install mount rubber using a suitable adhesive.
18. Apply suitable lubricant to bellows fitting position of tie rod, then install new attaching band to the bellows.
19. Fill inside of dust cover with a suitable lubricant, then place dust cover into position with clip ring attached to groove at tie rod end.

Fig. 41 Tie Rod Length Adjustment:

20. Install tie rods until free length of left and right rods are 6.1-6.2 inch, Fig. 41.