Overhaul

STEERING GEAR BOX

DISASSEMBLY
1. Remove the dust packing & cap (A) from the pinion housing.





2. Loosen the lock nut and then remove the tie rod end (B) and lock nut (A) from the tie rod.





3. Remove the bellows clip (A) and band (B) and then pull the bellows (C) away from the end of the tie rod.





4. Remove the tie rod (B) from the rack bar (A) by unscrewing the tie rod inner ball joint.





5. Remove the plug (A) from the pinion housing.





6. Remove the oil seal (B) from the plug (A).





7. Remove the yoke plug (A) and spring (B) and then pull out the support yoke (C).





8. Remove the O-rings (B) from the support yoke assembly (A).





9. Pull the pinion assembly (A) out of the pinion housing.





10. Pull the rack bar (A) out of the rack housing.





INSPECTION
1. Rack bar
- Check the rack gear for damage.
- Check the rack bar for bend and deformation.
2. Pinion assembly
- Check the pinion gear for damage.
- Check the surface contacting the oil seal for damage.
- Check the oil seal for damage.
3. Check the inside of rack housing for damage.
4. Check the bellows for being torn.

REASSEMBLY
1. Apply the grease to rack year teeth and then insert the rack bar (A) into the rack hosing.





2. Insert the pinion assembly (A) into the pinion housing.





3. Tap the top of the pinion assembly with a plastic hammer to seat the pinion assembly thoroughly.





4. Assemble new O-rings (B) to support yoke (A).





5. Insert the support yoke assembly (C) into the housing.
6. Apply the sealant to the thread of the yoke plug and then assemble the yoke plug (A) and the yoke spring (B) together.





7. Apply the grease to the edge of the new oil seal (B) and then assemble it to the pinion plug (A).





8. Apply the sealant to the thread of the plug and then assemble the pinion plug (A) to the housing.





9. Apply Loctite (Three bond-1374) to the thread of the tie rod inner ball joint and then assemble the tie rod (A) to the rack bar (B).





10. Assemble new bellows band (A) to the bellows.





11. Apply the grease (Kyoto Yushi-One Luber 2128 to the portion (D) of the tie-rod.
12. Apply the sealant (Three bond-1 141 E) to the bellows mating surface of the rack housing.
13. Assemble the bellows (C) to rack housing and then tighten the bellows clip (A) and band (B).





14. Assemble the lock nut (A) and tie rod end (B) to tie rod.