Disassemble
1. Thoroughly clean exterior of steering gear.
2. Remove plugs from pinion housing ports and purge any remaining fluid by turning pinion gently from lock to lock.
3. Center pinion gear and note location of pinchbolt groove.
4. Remove mounting bushings and sleeves.
5. Release nuts securing hydraulic lines to pinion valve housing and rack body.
6. Remove hydraulic lines from rack assembly, then the sealing washer from port in the pinion end rack housing.
7. Note position and release two large clips securing boots to pinion and end housings.
8. Pull boots to allow access to inner tie rod assemblies.
9. Push back tab washers securing inner tie rod locknuts to rack.
NOTE: Do not disturb tab washers between locknuts and ball pin housings.
10. Hold one inner tie rod assembly with a spanner wrench and loosen opposite tie rod.
11. Protect rack teeth and back of rack. Clamp rack to enable other tie rod to be released.
12. Unscrew tie rod assemblies from rack.
13. Remove springs and packing pieces, if equipped.
14. Release locknut securing rack damper.
15. Remove nut, threaded plug, spring and rack damper pad.
Fig. 8 O-ring, Spring & Rack Damper Pad Removal:
16. If rack damper adjustment is satisfactory and rack damper does not require overhaul, then remove two bolts and lift off plate. Remove O-ring, spring and rack damper pad.
END HOUSING
End Housing:
1. Release small hexagon socket set screw in end housing.
2. Using service tool No. S355 or equivalent, remove ring nut from end housing.
3. Remove end housing from rack tube.
4. Remove air transfer line and sealing rings from both pinion and end housings.
PINION VALVE & HOUSING
Fig. 9 Pinion Valve & Housing Removal:
1. Remove three self locking nuts securing pinion and valve assembly to pinion end rack housing.
2. Note relationship of ports to rack and remove complete pinion and valve assembly.
3. Remove sealing ring (2), pinion seal (3) and backing washer (4).
4. Gently tap pinion valve from pinion valve housing.
5. Remove circlip washer and ball bearing race, from valve assembly, if a replacement is required.
6. Pinion valve cannot be further dismantled and must be replaced as a complete assembly.
RACK & INNER SLEEVE
Fig. 10 Rack & Inner Sleeve Disassembly:
Fig. 11 Piston Ring & Backing Ring Removal:
1. Remove hexagon socket grub screw (1) from pinion end rack housing.
2. Pull out sealing washer (2).
3. Remove rack complete with inner sleeve (3) from bore of rack tube.
NOTE: Removal of inner sleeve over rack teeth will destroy seal (6).
4. Bend up retaining rings on seal cap (4) and remove cap from inner sleeve.
5. Remove seal O-ring (5), seal (6) and split bearing (7).
6. Remove rubber O-ring (8) and nylon washer (9) from bottom of rack tube.
7. Piston cannot be removed from rack, but piston ring (1) and backing ring (2) can be replaced.
8. Rack tube cannot be removed from plain (pinion end) rack housing, but ring nut and circlip may be replaced. Use caution when removing and replacing circlip over ground sealing outer diameter of rack tube.