Overhaul

DISASSEMBLY AND REASSEMBLY





LUBRICATION AND SEALING POINTS

DISASSEMBLY SERVICE POINTS
]]A[[ TIE ROD/TAB WASHER REMOVAL





Unstake the tab washer which secures the tie rod and rack with a chisel.

]]B[[ RACK SUPPORT COVER REMOVAL





Using special tool MB991204, remove the rack support cover from the gear box.

]]C[[ OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL





Using a plastic hammer, gently tap the pinion to remove it.

]]D[[ SEAL RING REMOVAL





CAUTION: When cutting the seal ring, be careful not to damage the pinion and valve assembly or the rack.

Cut the seal ring and remove it from the pinion and valve assembly and the rack.

]]E[[ BALL BEARING/OIL SEAL REMOVAL





Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously.

]]F[[ CIRCLIP REMOVAL





CAUTION: If the rack stopper is first turned counterclockwise, the circlip will get caught in the slot in the housing and the rack stopper will not turn.

1. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing.
2. Turn the rack stopper counterclockwise to remove the circlip.

]]G[[ RACK REMOVAL





Pull out the rack slowly. At this time also take out the rack stopper and the rack bushing simultaneously.

]]H[[ 0IL SEAL REMOVAL





CAUTION: Do not damage oil seal press fitting surface.

Partially bend oil seal and remove from rack bushing.

]]I[[ BALL BEARING REMOVAL





Use a brass bar or special tool MB990939 to remove the ball bearing from the gear housing.

]]J[[ NEEDLE ROLLER BEARING REMOVAL





CAUTION: Do not open special tool MB991120 excessively to prevent damaging housing interior.

Use special tool MB991120 to remove the needle roller bearing from the rack housing.

]]K[[ OIL SEAL REMOVAL





CAUTION: Be careful not to damage the inner surface of the rack cylinder of the gear housing.

Use a piece of pipe or similar tool to remove the oil seal from the gear housing.

REASSEMBLY SERVICE POINTS
]]A[[ OIL SEAL INSTALLATION





1. Apply a coating of the DIAMOND ATF to the both sides of the oil seal.
2. Using special tools MB991199 and MB991197, press the oil seal into the rack housing.

]]B[[ NEEDLE ROLLER BEARING/BALL BEARING INSTALLATION

CAUTION: Press-fit straight. Valve housing is aluminum, and may become deformed if Press-fit on an angle.





1. Apply DIAMOND ATF to housing, bearing and oil seal press fitting surface.
2. Press fit needle roller bearing with special tools MB990938 and MB991202.

]]C[[ OIL SEAL/D-RING INSTALLATION





1. Apply a coating of the DIAMOND ATF to the outside of the oil seal and O-ring.
2. Use special tool MB990927 to press fit oil seal until it touches rack bush end.

]]D[[ RACK INSTALLATION

CAUTION: Do not close the vent hole in the rack with grease.





1. Apply a coating of multipurpose grease to the rack teeth face.





2. Cover rack serrations with special tool MB991213.
3. Apply DIAMOND ATF to special tool MB991213.
4. Align center of oil seal with rack to prevent retainer spring from slipping. Slowly insert rack from power cylinder side.

]]E[[ RACK BUSHING INSTALLATION





CAUTION: Do not allow oil seal refiner spring to slip out.

Wrap the rack end with vinyl tape, apply a coating of the DIAMOND ATF, and then install the rack bushing and rack stopper.

]]F[[ CIRCLIP INSTALLATION





CAUTION: Insert circlip to rack stopper hole whilst turning rack stopper clockwise.

Insert circlip to rack stopper hole through cylinder hole. Turn rack stopper clockwise and insert circlip firmly.

]]G[[ OIL SEAL/BALL BEARING INSTALLATION





Apply a coating of the DIAMOND ATF to the outside of the oil seal/ball bearing. Using special tools MB990938 and MB991203, press the oil seal/ball bearing into the valve housing.

]]H[[ SEAL RING INSTALLATION





Because the seal rings expand after installation, tighten after installing by using special tool MB991317 to compress the rings, or press down by hand.

]]I[[ OIL SEAL INSTALLATION





CAUTION: To eliminate a seal malfunction at the valve housing alignment surface, the upper surface of the oil seal should project outward approximately 1 mm (0.04 inch) from the housing edge surface.

Using special tool MB991152, press the oil seal into the valve housing.

]]J[[ END PLUG INSTALLATION





1. Apply the 3M AAD Part number 8672, 8679, 8678, 8661, 8663 or equivalent to the threaded part of the end plug.
2. Secure the threaded portion of the end plug at two places by using a punch.

]]K[[ RACK SUPPORT COVER/JAM NUT INSTALLATION
1. Position rack at its center.
2. Apply the 3M AAD Part number 8672, 8679, 8678, 8661, 8663 or equivalent to the threaded part of the rack support cover.





3. Use special tool MB991204 to tighten rack support cover to 13 ± 2 Nm (109 ± 21 inch lbs.).
4. Turn the rack support cover by 10 degree counterclockwise.
5. Use special tool MB991204 to hold the rack support cover, and then tighten the jam nut to 59 ± 10 Nm (44 ± 7 ft. lbs.).

]]L[[ PINION TORQUE ADJUSTMENT

CAUTION:
^ When adjusting, set at the highest value of the standard value range.
^ Be sure there is no ratcheting or catching when operating the rack towards the shaft.
^ Measure the tool pinion torque through the whole stroke of the rack.

NOTE: If the tote/ pinion toque cannot be adjusted to the standard value within the specified return angle, check the rack support cover components and replace any parts if necessary.





1. Using special tool MB990228 or MB991006, rotate the pinion shaft at the rate of one rotation in four to six seconds to check the total pinion torque and the change in torque.
Standard value:
Tool pinion torque: 0.8 - 1.9 mm (6.9 - 16.5 inch lbs.)
Change in torque: 0.7 Nm (6.1 inch lbs.) or less]
2. If the total pinion torque or the change in torque is outside the standard value, return the rack support cover within 0 degree angle to 30 degree angle, and adjust again.

]]M[[ TAB WASHER/TIE ROD INSTALLATION





After installing tie rod to rack, fold tab washer end (two locations) to tie rod notch.

]]N[[ BELLOWS BAND INSTALLATION





1. Turn the adjusting bolt of special tool MB991561 to adjust the opening dimension (W) to the standard value.

NOTE: The dimension (W) is adjusted by approximately 0.7 mm (0.03 inch) per one turn.

NOTE: Do not turn the adjusting bolt more than one turn.

Standard value (W): 1.9 mm (0.07 inch)
When more than 1.9 mm (0.07 inch)]: Screw in the adjusting bolt.
When less than 1.9 mm (0.07 inch)]: Loosen the adjusting bolt.





CAUTION:
^ Hold the rack housing, and use special tool MB991561 to crimp the bellows band securely.
^ Crimp the bellows band until special tool MB991561 touches the stopper.

2. Use special tool MB991561 to crimp the bellows band.





3. Check that crimped width (A) is within the standard value.
Standard value (A): 1.4 - 1.8 mm (0.06 - 0.07 inch)
When more than 1.8 mm (0.07 inch)]: Readjust the dimension (W) of step (1) to the value calculated by the following equation, and repeat step (2).
W = 5.5 mm (0.22 inch) - A [Example: if (A) is 1.9 mm (0.07 inch), (W) is 3.6 mm (0.14 inch).
When less than 1.4 mm (0.06 inch)]: Remove the bellows band, readjust the dimension (W) of step (1) to the value calculated by the following equation, and use a new bellows band to repeat steps (2) to (3).
W = 5.5 mm (0.22 inch) - A Example: if (A) is 1.3 mm (0.05 inch), (W) is 4.2 mm (0.17 inch).

]]O[[ TIE ROD END/TIE ROD END JAM NUT INSTALLATION





Screw in the tie rod end to achieve the right and left length as illustrated. Lock with the jam nut

INSPECTION
RACK
^ Check the rack tooth surfaces for damage or wear.
^ Check the oil seal contact surfaces for uneven wear.
^ Check the rack for bends.

PINION AND VALVE ASSEMBLY
^ Check the pinion gear tooth surfaces for damage or wear.
^ Check for worn or defective seal ring.

BEARING
^ Check for roughness or abnormal noise during bearing operation.
^ Check the bearing for play.
^ Check the needle roller bearings for roller slip-off.

OTHERS
^ Check the cylinder inner surface of the rack housing for damage.
^ Check the boots for damage, cracking or deterioration.
^ Check the rack support for uneven wear or dents.
^ Check the rack bushing for uneven wear or damage.

TIE ROD END BALL JOINT DUST COVER REPLACEMENT





If the dust cover is damaged accidentally during service work, replace the dust cover as follows:
1. Apply grease to the lip and inside of the dust cover.
2. Drive in the dust cover with special tool MB990776 until it is fully seated.
3. Check the dust cover for cracks or damage by pushing it with your finger.