Disassembly

TOOL REQUIRED
^ 926200000 Stand
^ 927590000 Wrench
^ 34099PA100 Wrench
^ 927580000 Remover
^ 34099PA00 Former

DISASSEMBLE





1. Secure gearbox removed from vehicle in vice using STAND. Secure the gearbox assy in a vice using the special tool as shown. Do not attempt to secure it without this special tool.
2. Disconnect the two pipes in/out from gear box after removal of pipe clamp.





3. Disconnect pipes A and B from steering body and control valve housing. Replace pipes and/or flare nuts if damaged.
4. Remove tie-rod end and lock nut.





5. Pry off clip from small end of boot, and slide it toward tie-rod end.





6. Using special tool, remove lock wire from large end of boot.








7. Cut and remove the boot. Boot must be replaced with a new one whenever it is removed.





8. Set rack so that it protrudes about 40 mm (1 57 inch) outside. Pry clinched portion of tie-rod lock washer with standard screwdriver (both left and right side)
a. Be careful not to scratch rack, since it can cause oil to leak.
b. Tie-rod lock washer must be replaced with a new one whenever it is removed.





9. Using special tool, loosen lock nut. Tighten adjusting screw until it no longer tightens





10. Using WRENCH [32 mm (1.26 inch) width across flats, (P/N 34099PA100) or adjustable wrench, remove tie-rod CP.
a. Check ball joint for free play, and tie-rod for bends; replace if necessary.
b. Check dust seals used with tie-rod end ball joint for damage or deterioration. Replace if necessary.
11. Loosen adjusting screw and remove spring and sleeve Replace spring and/or sleeve if damaged.
12. Removal of valve assy





a. Remove the two bolts securing valve housing assy.





b. Remove valve housing assy, pinion and valve assy as a unit. Extract input shaft when removing valve assy.





13. Removal of snap ring from seal holder assy While attaching small screwdriver blade to snap ring via groove on boot (on cylinder side of steering body assy), push the snap ring using another screwdriver





14. Removal of rack assy Push rack out of steering body assy while pushing it on valve side.
a. Block pipe connection of steering body assy to prevent fluid from flowing out.
b. Do not allow rack to come in contact with inner wall of cylinder. Otherwise, cylinder wall may be scratched, resulting in oil leaks.
c. Remove holder assy and rack assy as a unit.
d. Check rack and steering body assy for bends or cracks; replace as required.





15. Removal of high-pressure seal Insert REMOVER from valve side, and lightly tap it using a hammer to drive out back-up ring and oil seal. Discard back-up ring and oil seal after removal; replace with new ones.





16. Removal of oil seal and O-ring
a. Using a small rod, pry out oil seal.

NOTE: Be careful not to scratch oil seal groove on holder assy. A scratch may cause oil leaks. Be careful not to scratch mating surfaces of holder assy and racy A scratch may cause oil leaks. Check rack bushing for wear or damage; replace as required. Discard oil seal and O-ring after removal; replace with new ones.

b. Remove O-ring.
c. Apply a coat of grease to oil seal groove in holder assy.
d. Install a new oil seal and O-ring.
17. Removal of rack piston seal ring and O-ring





a. Using a sharp-edged, long rod, remove seal ring and O-ring from rack piston. Be careful not to scratch outer surface of rack piston and seal ring groove. A scratch may reduce the sealing effect, resulting in faulty piston operation.
b. Wash clean rack piston.





c. Install O-ring and seal ring in groove on rack piston.

NOTE: Do not expand O-ring and seal ring more than necessary. To facilitate installation of seal ring, first position one half of entire seal ring in groove. Then slowly position the second half using a spatula, as shown.





d. Apply a coat of grease to inner surface of FORMER (special tool) and insert rack piston into it. Leave FORMER at least 10 minutes until seal ring settles down in place. Be careful not to scratch rack, piston and seal ring during installation.