Disassembly And Assembly

STEERING GEAR AND LINKAGE


Disassembly and Assembly












CAUTION:
- Secure the gear housing assembly with a vise. Use copper plates or equivalent to prevent it from being damaged. Do not grip the cylinder with a vise.
- Before performing disassembly, clean the gear housing assembly. Be careful not to allow any cleaner to contact the discharge and return port connectors.

DISASSEMBLY
1. Remove the cylinder tubes from the gear housing assembly.
2. Loosen the lock nuts of the outer sockets, then remove the outer sockets from the inner sockets.
3. Remove the boot clamps from the boots, then remove the boots from the inner sockets and gear housing assembly.

CAUTION:
- Do not reuse the large-diameter boot clamps.
- Do not damage the boots, inner socket or gear housing assembly. If they are damaged, replace them.
4. Remove the inner sockets.

INSPECTION AFTER DISASSEMBLY

Boot
Check boot for tears, cracks and deformation. Replace if necessary.

Gear Housing Assembly
Check gear housing assembly for dents, cracks or damage. Replace as an assembly if necessary.

Outer Socket and Inner Socket

SWING TORQUE





- Measure the swing torque, using Tool. When ball stud and inner socket start moving the measured value must be within the specification. If the reading is outside the specification, replace the socket.

Tool number : - (J-44372)







ROTATING TORQUE





- Measure the rotating torque, using Tool. If the value is outside the specification, replace the outer sockets. Steering Gear Outer And Inner Socket

AXIAL END PLAY





- Apply a load of 490 N (50 kg-f, 110 lb-f) to the ball stud axially. Use a dial gauge to measure the amount of the movement that the stud makes. If the value is outside the specification, replace the sockets.





ASSEMBLY
1. Install the inner sockets.





2. Install the large-diameter side of the boots to the gear housing assembly.
3. Install the small-diameter side of the boots to the groove of the inner sockets.





4. Install the boot clamps to the boots, as shown.

CAUTION:
Do not reuse the large boot clamps.





5. Crimp the large boot clamps, using Tool.

Tool number : KV40107300 ( - )

6. Install the cylinder tubes to the gear housing assembly.
7. Install the lock nuts and outer sockets to the inner sockets.





8. Thread the outer sockets onto the inner sockets to the specified length (L), then tighten the lock nuts to the specified torque. Refer to "Disassembly and Assembly". Reconfirm that the tie-rod length (L) is within specification.

Maximum inner socket length (L) : Steering Gear Outer And Inner Socket