Disassembly
Disassembly
1. Remove the tie rod end from the tie rod.
2. Remove the dust cover from the ball joint.
3. Remove the bellows band.
4. Remove the bellows clip.
5. Pull the bellows out toward the tie rod.
Note: Check for rust on the rack when the bellows are replaced.
6. Remove the feed tubes from the gear housing.
7. While moving the rack slowly, drain the fluid from the gear housing.
8. Unstake the tab washer which fixes the tie rod and rack with a chisel.
9. Remove the tie rod from the rack.
Caution: Remove the tie rod from the rack, taking care not to twist the rack.
10. Remove the rack support plug lock nut.
11. Using the special tool (09565-31300), remove the rack support plug.
12. Remove the rack support spring, rack support and bushing from the gear box.
13. Remove the end plug self-locking nut.
14. Detach the dust seal.
15. Remove the snap ring with a snap ring plier.
16. Remove the pinion and valve assembly together with the oil seal (upper) using a soft hammer.
17. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the gear housing.
18. When the end of the circlip comes out from the notched hole of the housing rack cylinder, turn the rack stopper counter clockwise and remove the circlip.
Caution: Do not damage the rack.
19. Remove the rack stopper, rack bushing and rack from the gear housing by moving it toward the piston side.
Caution: When the rack has been removed, be sure to replace the housing side oft seal with a new one.
20. Remove the O-ring from the rack bushing.
21. Remove the oil seal from the rack bushing.
22. Drive out the ball bearing using special tool (09517-21400) and hammer.
Caution: Do not damage the pinion valve cylinder inside of the gear housing.
23. Drive out the needle bearing and oil seal.
24. Use the special tools (09555-21000, 09573-33100) to remove the back washer and oil seal from the gear housing.
Caution: Do not damage the rack cylinder inside of the gear housing.