Diassembly, Inspection and Reassembly

Fig. 22 Exploded View Of Power Steering Gear:

Disassemble power steering gear in numbered sequence shown in Fig. 22, noting the following:
1. Using a screwdriver, remove dust cover from tie rod end. Loosen, then remove boot retaining band.
2. Using a chisel, unstake tab washer which fixes tie rod and rack.
3. Remove end plug caulking and end plug.
4. Using special tool No. MB991204, or equivalent, remove rack support cover from gearbox.
5. Using a plastic hammer, gently tap the pinion to remove it.
6. Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously.
7. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing, then turn the stopper counterclockwise to remove the circlip.
8. Remove rack, rack stopper and rack bushing.
9. Partially bend oil seal and remove from rack bushing. Do not damage oil seal press fitting surface.
10. Using a brass bar, remove the ball bearing from the gear housing.
11. Using special tool No. MB991120, or equivalent, remove the needle roller bearing from the rack housing.
12. Remove the back-up washer and oil seal from the gear housing, using caution to avoid damaging inner surface of rack cylinder.
13. Inspect the rack tooth surfaces for damage or wear, then the oil seal contact surfaces for uneven wear.
14. Inspect the rack for bends.
15. Check the pinion gear tooth surfaces for damage or wear, then check for worn or defective seal.
16. Check bearing for roughness or abnormal noise during operation, check the bearing for play.
17. Check the needle roller for bearings for roller slip-off.
18. Check the cylinder inner surface of the rack housing for damage.
19. Check mounting rubber for cracks or damage. Replace as required.
20. Reverse numbered sequence shown in Fig. 22 to assemble steering gear, noting the following.
a. When installing back-up washer and oil seal, coat seal with Dexron II or Diamond ATF SP ATF and press washer and seal into rack housing to specified position.
b. When installing needle roller bearing, press evenly as valve housing is aluminum.
c. When installing oil seal and O-ring, press fit oil seal until it reaches rack bush end.
d. Apply coating of multipurpose grease to rack tooth face.
e. When installing rack assembly, cover rack serrations with tool No. MB991213, or equivalent, then match oil seal center with rack to prevent retainer spring from slipping and slowly insert rack from power cylinder side.
f. When installing rack bushing and stopper, wrap rack end with vinyl tape and apply a coating of Dexron II or Diamond ATF SP ATF.
g. Install seal rings using tool No. MB991317, or equivalent.
h. When installing end plug, secure threaded portion at two points using a punch.
i. Adjust total pinion torque to 5-11 inch lbs.
j. When installing tie rod, fold tab washer end into tie rod notch.
k. Pack dust cover interior with multi-purpose grease.