Disassembly
REASSEMBLY
DISASSEMBLY AND REASSEMBLY
1. If it is necessary to remove the key lock assembly, use a pinch to make a groove on the head of the special bolt, and then use a screwdriver to remove the key lock assembly mounting bracket.
2. Disassemble the key lock assembly from the steering column shaft.
3. Reassembly is the reverse of disassembly.
DISASSEMBLY
1. Remove the feed tube.
2. Remove the tie rod end from the tie rod.
3. Remove the dust cover from the ball joint.
4. Remove the bellows band.
5. Remove the bellows clip. 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 lock nut.
11. Using the special tool (09565-31300), remove the yoke plug.
12. Remove the rack support spring, yoke support and bushing from the gear box.
13. Remove the end plug and self-locking nut.
14. Detach the dust seal.
15. Remove the snap ring with snap ring pliers.
16. Remove bolts mounting the valve assembly to the rack housing.
17. Remove the pinion and valve assembly together with the oil seal (upper) using a soft hammer.
18. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the gear housing.
19. 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 when disassembling.
20. Remove the rack stopper, rack bushing and rack from the rack housing by moving it toward the piston side.
CAUTION:
When the rack has been removed, be sure to replace the housing side oil seal with a new one.
21. Remove the O-ring from the rack bushing.
22. Remove the oil seal from the rack bushing.
