Overhaul

Steering Gearbox Overhaul

Exploded View





Special Tools Required

- Cylinder End Seal Remover Attachment 07NAD-SR3020A
- Piston Seal Ring Guide 07HAG-SF10100
- Sizing Tool, 42 mm 07HAG-SF1020A or 07HAG-SF10200
- Cylinder End Seal Slider 07ZAG-S5A0300
- Pincers Oetiker 1098, commercially available

NOTE: Refer to the Exploded View as needed during this procedure.

Disassembly

1. Remove the steering gearbox Steering Gearbox Removal.

2. Remove the boot bands (A) and tie-rod clips (B). Pull the boot away from the ends of the steering gearbox.






3. Unbend the lock washer (A).






4. Hold the flat surface sections (A) of the steering rack with a wrench (B), and unscrew both rack ends (C) with another wrench (D). Be careful not to damage the rack surface with the wrench.





5. Remove the lock washer (E) and rubber stop (F).

6. Loosen the locknut (A), then remove the rack guide screw (B).





7. Remove the spring (C) and the rack guide (D) from the gearbox housing.

8. Remove the cylinder lines from the steering gearbox.

NOTE: Use a second wrench when loosening the cylinder lines to avoid damaging to the fittings on the steering gearbox. Do not loosen the A and B connectors.





9. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth.

10. Remove the ECPS valve (A) and O-rings (B), then remove the connector holder mounting bolt (C) on the valve housing.






11. Drill a 4.0 mm (0.158 in) diameter hole about 2.5-3.0 mm (0.098-0.118 in) in depth in the staked point (A) on the end plug (B) and the gearbox housing (C).






12. Remove the end plug (A) from the gearbox housing, then remove a pinion nut (B) from the pinion shaft end.






13. Remove the flange bolt, the valve body unit (A), and the gasket (B) from the gearbox housing. Check that the valve turns smoothly by turning the pinion shaft. If any play or roughness is felt, replace the valve body unit with a new part.





14. Slide the steering rack all the way to the left.

15. Wrap vinyl tape (A) to the splines on the pinion shaft.






16. Separate the valve housing (A) from the pinion shaft/sleeve (B), then remove the pinion oil seal (C).






17. Drill a 3.0 mm (0.118 in) diameter hole about 2.5-3.0 mm (0.098-0.118 in) in depth in the staked point (A) on the cylinder (C). Do not allow metal shavings to enter the cylinder housing. After removing the cylinder end (B), remove any burrs at the staked point.






18. Hold the gearbox housing using a C-clamp (commercially available) (A) and wooden blocks (B) to a work bench as shown. Do not clamp the cylinder part of the gearbox housing in the vise. Then remove the cylinder end (C).






19. Install a commercially available bearing separator (A) in the gearbox housing as shown.






20. Place an appropriate size extension (B) on the steering rack (C).

21. Set the steering gearbox in a press so the gearbox housing side points upward, then press the cylinder end seal (D) and steering rack out of the gearbox. Hold the steering rack to keep it from falling when pressed clear. Be careful not to damage the inner surface of the cylinder housing with the tool.

22. Install the cylinder end seal remover attachment (A) so it will fit through the rack guide hole of the gearbox housing. Insert a 24'' long, 3/8'' drive extension (B), and install it on the cylinder end seal remover attachment. Make sure the cylinder end seal remover attachment is securely positioned on the backup ring edges. Be careful not to damage the inner surface of the cylinder with the cylinder end seal remover attachment.






23. Place the steering gearbox in a press, then remove the cylinder end seal (A) and backup ring (B) from the gearbox by pressing on the 24'' long, 3/8'' drive extension.

Note these items when pressing the cylinder end seal:

- Keep the tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it if necessary, when removing the cylinder end seal.
- Use a press to remove the cylinder end seal. Do not try to remove the seal by striking the tool; striking the tool could break the backup ring, and the cylinder end seal would remain in the gearbox housing.





24. Carefully pry the piston seal ring (A) and the O-ring (B) off the rack piston. Be careful not to damage the inside of the seal ring groove and piston edges when removing the seal ring.






Reassembly

25. Coat the piston seal ring guide with power steering fluid, then slide it onto the rack, big end first.

26. Position a new O-ring (A) and a new piston seal ring (B) on the piston seal ring guide, then slide them down toward the big end of the tool.

Note these items during reassembly:

- Do not over expand the resin seal rings. Install the resin seal rings with care so as not to damage them. After installation, make sure you contract the seal ring using the piston seal ring guide.
- Replace the piston's O-ring and seal ring as a set.





27. Pull the O-ring off into the piston groove, then pull the piston seal ring off into the piston groove on top of the O-ring.

28. Coat the piston seal ring (A) and the inside of the piston seal ring sizing tool with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.





29. Move the piston seal ring sizing tool back and forth several times to make sure the piston seal ring fits snugly in the piston.

30. Coat the sliding surface of the cylinder end seal slider (A) and the new cylinder end seal (B) with power steering fluid. Place the seal on the cylinder end seal slider with its grooved side (C) facing opposite the cylinder end seal slider.






31. Coat the surface of the steering rack (A) with power steering fluid.





32. Install the cylinder end seal (B) onto the steering rack with its grooved side (C) toward the piston (D).

33. Separate the cylinder end seal from the cylinder end seal slider, then remove the cylinder end seal slider.

34. Install a new backup ring (A) on the steering rack, then place the backup ring and the cylinder end seal (B) against the piston (C).






35. Apply steering grease (08C35-B0534L) to the steering rack teeth, then insert the steering rack into the gearbox housing. Be careful not to damage the inner surface of the cylinder wall with the rack edges.






36. Insert an appropriate size deep socket (A) onto the steering rack as shown.





37. Install the cylinder end seal (B) into the bottom of the cylinder by pressing on the tool with a press. Do not push on the tool with excessive force as it may damage the cylinder end seal.

38. Remove the tool, and center the steering rack.

39. Coat the sliding surface of the cylinder end seal slider (A) and a new cylinder end seal (B) with power steering fluid. Place the seal on the cylinder end seal slider with its grooved side (C) facing opposite the cylinder end seal slider.






40. Coat the inside surface of the cylinder end seal slider and steering rack with power steering fluid, then install the cylinder end seal (A) onto the steering rack with its grooved side toward the cylinder.





41. Separate the cylinder end seal from the cylinder end seal slider, then remove the cylinder end seal slider.

42. Push in the cylinder end seal with your finger. Be careful not to damage the face of the seal with the threads and burrs at the staked position of the cylinder housing.

43. Hold the gearbox housing using a C-clamp (commercially available) (A) and wooden blocks (B) as shown. Do not clamp the cylinder part of the gearbox housing in the vise.






44. Coat the inside surface of the cylinder end (A) with power steering fluid, then install the cylinder end by screwing it into the cylinder (B). Tighten the cylinder end to the specified torque.





45. Stake (C) the point of the cylinder shown (opposite from where the stake was removed during disassembly).

46. Wrap vinyl tape (A) to the pinion shaft/sleeve, then coat the vinyl tape with power steering fluid.





47. Insert the pinion shaft/sleeve and a new pinion oil seal (B) into the valve housing (C). Be careful not to damage the valve seal rings (D).

48. Remove the vinyl tape from the pinion shaft, then remove any residue from the tape adhesive.

49. Press the pinion shaft/sleeve into the valve housing with a hydraulic press. Check that the pinion shaft/sleeve turns smoothly by hand after installing it.






50. Apply steering grease (08C35-B0534L) to the bearing (A) in the gearbox housing, and install the valve body unit (B) and a new gasket (C) by engaging the gears. Note the valve body unit installation position (direction of line connections). Then loosely install the flange bolt (D).






51. Coat new O-rings (A) with power steering fluid, then install the O-rings and the ECPS valve motor (B).





52. Loosely install the flange bolt (C).

53. Install a new pinion nut (A) onto the pinion shaft end, and tighten to the specified torque.





54. Tighten the flange bolts on the valve body unit to the specified torque.

55. Remove the old sealant from the gearbox housing (B), and apply new sealant (Three Bond 1215 or Loctite 5699) all the way around the threads on a new end plug (C). Install the end plug onto the gearbox housing, then tighten it to the specified torque.

NOTE: If more than 5 minutes has passed after applying the sealant, remove the old sealant and residue, and reapply new sealant.

56. After tightening, use a drift to stake (A) the end plug shoulder against the gearbox housing.






57. Before installing the cylinder lines, coat new O-rings (A) with power steering fluid, then install the lines (B).

Note these items during reassembly:

- Thoroughly clean the joints of the cylinder lines. The joints must be free of foreign material.
- Install the cylinder lines by tightening the flare nuts by hand first, then tighten the flare nuts to the specified torque.

NOTE: Use a second wrench when tightening the cylinder lines to avoid damaging the fittings on the steering gearbox.






58. Apply steering grease (08C35-B0534L) to the sliding surface of the rack guide (A), and install it onto the gearbox housing.





59. Remove the old sealant from the rack guide screw (B), and apply new sealant (Three Bond 1215 or Loctite 5699) to the middle of the threads of the rack guide screw, then install the spring (C), the rack guide screw, and the locknut (D).

NOTE: If more than 5 minutes has passed after applying the sealant, remove the old sealant and residue, and reapply new sealant.

60. Adjust the rack guide screw Adjustments. After adjusting, check that the rack moves smoothly by sliding it right and left.

61. Install a new rubber stop (A) and a new lock washer (B). Align the lock washer tabs (C) with the slots (D) on the rack end (E) while holding the lock washer in place. Repeat this step for the other side of the rack.





62. Hold the flat surface sections of the steering rack with a wrench, and tighten both rack ends with another wrench. Be careful not to damage the rack surface with the wrench.

63. Bend the lock washer (A) back against the flat spots on the rack end joint housing.






64. Apply multipurpose grease to the circumference of the rack end joint housing (A).





65. Apply a light coat of silicone grease (P/N 08798-9013) to the boot grooves (B) on the rack ends.

NOTE: Make sure not to get any silicone grease on the terminal part of the connectors, especially if you have silicone grease on your hands or gloves.

66. Center the steering rack within its stroke.

67. Clean off any grease or contamination from the boot installation grooves (A) and around on the gearbox housing. Install the boots (B) on the rack ends with the tie-rod clips (C), and fit the boot end in the installation grooves in the housing properly.





68. After installing the boots, wipe the grease off the threaded section (D) of the rack end.

69. Install new boot bands (A) by aligning the tabs (B) with the holes (C) on the band.






70. Close the ear portion (A) of the boot band (B) with pincers Oetiker 1098, commercially available or equivalent (C).





71. Slide the rack right and left to be certain that the boots are not deformed or twisted.

72. Install the tie-rod end to the rack end.

73. Install the steering gearbox Steering Gearbox Installation.