Disassembly

DISASSEMBLY





1. Remove the tie rod end from the tie rod.





2. After mounting the tie rod end in a vise, 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 tube from the rack housing.
7. While moving the rack slowly, drain the fluid from the rack 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 yoke plug locking nut.





11. Remove the yoke plug with a 14mm socket.





12. Remove the lock nut, yoke plug, rack support spring, rack support yoke and bushing from the gear box.





13. Remove the valve body housing by loosening the two bolts.





14. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing.





15. When the end of the circlip comes out of the notched hole of the housing rack cylinder, turn the rack stopper counterclockwise and remove the circlip.

CAUTION: Be careful not to damage the rack

16. Remove the rack stopper, rack bushing and rack from the rack housing.





17. Remove the O-ring from the rack bushing.





18. Remove the oil seal from the rack bushing.





19. Remove the valve body from the valve body housing with a soft hammer.
20. Using the special tool, remove the oil seal and ball bearing from the valve body housing.
21. Remove the oil seal and O-ring from the rack housing.

CAUTION: Be careful not to damage the pinion valve cylinder bore of the rack housing.





22. Using the special tool, remove the oil seal from the rack housing.

CAUTION: Be careful not to damage the rack cylinder bore of the rack housing.