Steering Gear And Linkage Disassembly

STEERING GEAR AND LINKAGE DISASSEMBLY

CAUTION:
- To prevent damage to the steering gear when securing it in a vice, always secure it using aluminum plates and clean rags.

1. Disassemble in the order indicated in the figure.













Tie-rod End Disassembly Note

1. Place alignment marks as shown in the figure for proper installation.






2. Remove the tie-rod end.

Tie rod, Tie-rod Lock Washer Disassembly Note

1. Unclamp the tie-rod lock washer tabs using a flathead screwdriver.






2. Install the SST to the flat surface of the tie rod, a wrench to the flat surface of the steering rack as shown in the figure and remove tie rod.






CAUTION:
- If a tool is installed to the SST (49 E032 308), install the tool so that it is perpendicular to the SST as shown in the figure. If the tool is not installed as instructed, the SST can separate from the tie rod easily which could cause damage to the tie rod while doing the work.

3. Remove the tie-rod lock washer.

Locknut (adjusting cover), Adjusting Cover Disassembly Note

1. Remove the locknut (adjusting cover) from the gear housing using the SST.






CAUTION:
- If a tool is installed to the SST (49 E032 308), install the tool so that it is perpendicular to the SST as shown in the figure. If the tool is not installed as instructed, the SST can separate from the locknut easily which could cause damage to the locknut while doing the work.

2. Remove the adjusting cover from the gear housing.

Pinion Shaft Component Disassembly Note

1. Remove the pinion shaft component from the valve housing using a press and steel plate.






Seal Ring Disassembly Note

1. Cut off the seal rings using a utility knife and remove them from the sleeve.

CAUTION:
- Be careful not to damage the sleeve and seal ring groove when cutting off the seal ring. Otherwise, the power steering system may not operate normally.

Bush, Oil Seal Disassembly Note

1. Remove the bush and oil seal from the valve housing using the SST and a press.






Substitution SST
- 49 S501 062
Outer diameter: 22 mm {0.87 in}
Height: 55 mm {2.2 in} or more

Cylinder End Disassembly Note

1. Remove the cylinder end from the gear housing using the SST.






Oil Seal (cylinder end side), Steering Rack Disassembly Note

1. Set the SST to the gear housing as shown in the figure.






2. Move the steering rack towards the oil seal (cylinder end side) until it stops.

3. Remove the oil seal (cylinder end side) and the steering rack from the gear housing using the SSTs and a press.






CAUTION:
- If the oil seal (cylinder end side) drops off, the steering rack could also fall off and be damaged. Put a mat under the steering rack to protect it from being damaged.

Seal Ring, O-ring Disassembly Note

1. Cut off the seal rings using a utility knife and remove them from the steering rack.

CAUTION:
- Be careful not to damage the steering rack and seal ring groove in the piston when cutting off the seal ring. Otherwise, the power steering system may not operate normally.

2. Remove the O-ring from the steering rack.

Oil Seal (pinion shaft side), Back-up Cylinder Ring Disassembly Note

1. Remove the oil seal (pinion shaft side) and the back-up cylinder ring from the gear housing using the SSTs and a press.






NOTE:
- If they cannot be removed using only the SSTs, set an appropriate rod to the upper part of the SSTs to perform the work.

Mounting Rubber Disassembly Note

1. Remove the mounting rubber from the gear housing using the SSTs and a press.





Substitution SST
- 49 B032 317
Outer diameter: 20.0-24.5 mm {0.79-0.96 in}
Height: 40 mm {1.6 in} or more
- 49 V001 525
Inner diameter: 34 mm {1.3 in} or more
Outer diameter: 36-39 mm {1.42-1.53 in}
Plate thickness: 1 mm {0.04 in} or more
Height: 40 mm {1.6 in} or more