Disassembly
TOOL REQUIRED^ ST 926340001 Wrench
^ ST 926340000 Wrench
^ ST 927610000 Installer
^ ST1 926370000 Installer A
^ ST2 927630000 Stand Base
^ ST3 926360000 Installer A
^ ST4 927620000 Installer B
^ ST3 927640000 Installer B
^ ST 927650000 Installer
1. Valve Assembly
a. Loosen two bolts securing valve assembly.
b. Carefully draw out input shaft and remove valve assembly.
c. Draw out pinion and valve assembly from valve housing, as necessary, using pipe of I.D. 44 to 46 mm (1.73 to 1.81 inch) and a press.
2. Rack Assembly
a. Slide mounting rubber to expose slit.
b. Rotate rack stopper in the direction of arrow using ST until the end of circlip comes out of stopper, then rotate it in the opposite direction, and pull out circlip.
NOTE: If ST is used, grind area (shown in figure) by 1 mm (0.04 inch) in advance.
c. Pull rack assembly from cylinder side, and draw out rack bushing and rack stopper together with rack assembly.
CAUTION: Be careful not to contact rack to inner wall of cylinder when drawing out. Any scratch on cylinder inner wall will cause oil leakage.
d. Remove rack bushing and rack stopper from rack assembly.
CAUTION: Do not reuse removed rack bushing and circlip.
3. Valve Housing Oil Seal
a. Pry off dust seal using screwdriver.
b. Remove snap ring using snap ring pliers.
c. Pry off oil seal using screwdriver.
CAUTION: After removing, check inside surface of valve housing for damage. If oil seal contacting surface is damaged, replace valve housing with a new one.
d. Press-fit oil seal into valve housing using ST and press.
NOTE: Before fitting, coat oil seal fully with ATF DEXRON II.
e. Pit snap ring in snap ring groove using snap ring pliers.
CAUTION: Be careful not to scratch oil seal with snap ring pliers.
NOTE: Rotate snap ring to check for proper installation.
4. Pinion And Valve Assembly
a. Remove snap ring using snap ring pliers.
CAUTION:
^ Do not reuse removed snap ring.
^ Be careful not to scratch pinion and valve assembly.
b. Press out bearing together with backing washer using pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555 inch) and press.
CAUTION: Do not reuse removed bearing.
c. Remove oil seal.
CAUTION: Do not reuse removed oil seal.
d. Fit pinion and valve assembly into valve housing.
NOTE: Apply ATF DEXRON II to outer diameter surface of input shaft and outer surface of valve body seal ring, and pay special attention not to damage seal when inserting pinion and valve assembly.
e. Secure valve assembly to ST1 and ST2.
f. Put ST3 over pinion, and insert oil seal, then force-fit oil seal into housing using ST4.
NOTE:
^ Apply ATE DEXRON II to oil seal and ST3, being careful not to damage oil seal lip.
^ Push oil seal until ST3 contacts housing end face.
g. Remove ST3, and fit backing washer.
h. Force-fit ball bearing using ST3.
NOTE: Be careful not to tilt ball bearing during installation.
i. Install snap ring using snap ring pliers.
NOTE: Rotate snap ring to check for proper installation.
5. Rack Housing Oil Seal And Back-up Washer
a. Insert a round rod [26 - 27 mm (1.02 - 1.06 inch) dia.] from pinion housing side and remove oil seal and back-up washer by hammering the rod.
NOTE:
^ Discard removed oil seal and back-up washer.
^ Apply the unchamfered end of remover to back-up washer.
b. Force-fit oil seal and back-up washer using ST.
CAUTION: Be careful not to damage or scratch cylinder inner wall.
NOTE:
^ Apply ATE DEXRON II to oil seal.
^ Pay special attention not to install back-up washer and oil seal in wrong direction.
^ Push oil seal until the stepped portion of A contacts end face of B.