Overhaul

Fig. 25 Exploded View Of Power Steering Gear:

1. Disassemble steering gear in numbered sequence shown in Fig. 25, noting the following:
a. Unstake tie rod end tab washer.
b. Using socket tool No. MB990607, or equivalent, remove rack support cover.
c. Using a plastic hammer, lightly tap on pinion shaft to remove.
d. Turn rack stopper clockwise until end of circlip is visible.

Fig. 26 Circlip Removal:

e. Turn rack stopper counterclockwise to remove circlip, Fig. 26.

Fig. 27 Rack Removal:

f. Remove rack slowly, Fig. 27.
g. Remove oil seal using suitable oil seal remover tool.
h. Remove ball bearing using brass bar tool No. MB990939, or equivalent.
i. Remove needle roller bearing using bearing tool No. MB991120, or equivalent.
j. Remove oil seal from housing using a piece of pipe.
2. Reverse numbered sequence shown in Fig. 25 to assemble, noting the following:
a. Using rack installer tool No. MB991212, or equivalent, press back-up washer and oil seal into rack housing.
b. Install needle roller bearing using bearing installation tool No. MB991120, or equivalent.
c. Apply a coat of multipurpose grease to rack teeth face. Do not close vent hose in rack with grease.
d. Cover rack serrations with special rack installer tool, apply Dexron II or Diamond ATF SP ATF fluid to tool.
e. Align oil seal center with rack to prevent retainer spring from slipping and slowly insert rack from power cylinder side.
f. Wrap vinyl tape around end of rack, and install rack bushing and stopper.

Fig. 28 Circlip Installation:

g. Insert circlip to rack stopper through cylinder hole. Turn rack stopper clockwise and insert circlip firmly, Fig. 28.
h. Apply multipurpose grease to pinion gear and housing, wrap tape around serrated part.
i. Use seal ring installer tool No. MB991317, or equivalent, to install seal ring, then install pinion and valve assembly into valve housing.

Fig. 29 Oil Seal Installtion:

j. Install valve housing seal using suitable seal installation tool and allow seal upper surface to project outward 0.040 inch, Fig. 29.
k. Apply 3M ATD sealant part No. 8663, or equivalent, to end plug threads, then install end plug securing in place using a suitable punch.
l. To adjust total pinion torque, center rack, then use torque wrench socket tool No. MB990607, or equivalent, to torque rack support cover to 11 ft. lbs. Then, from neutral position, rotate pinion shaft clockwise one turn within four to six seconds. Loosen rack support cover 30-60° and adjust torque to 5-11 inch lbs., then lock rack support cover with locknut.