Disassembly

Steering Gearbox

DISASSEMBLY

RACK HOUSING ASSEMBLY
1. Disconnect the four pipes from gearbox.

NOTE: Remove the pipes C and D, which are fixed to clamp plate, as a single unit.





2. Secure the gearbox removed from vehicle in vice using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D

CAUTION: Secure the gearbox in a vise using ST as shown. Do not attempt to secure it without this ST.

3. Remove the tie-rod end and lock nut from gearbox.





4. Remove the small clip from the boot using pliers and then move the boot to tie-rod end side.





5. Using a flat-tip screwdriver, remove the band from boot.

NOTE: Replace the boot it there is damage, cracks or deterioration.





6. Using the ST, loosen the lock nut.
ST 926230000 SPANNER





7. Tighten the adjusting screw until it no longer tightens.





8. Hold the rack with a wrench [22 mm width across flats], and then remove the tie-rod using a wrench [32 mm width across flats] or adjustable wrench.
9. Loosen the adjusting screw, and then remove the spring and sleeve.





10. Remove the two bolts securing valve assembly.





11. Carefully draw out the input shaft, and then remove the valve assembly.





12. Using a drill, release the caulking of holder.

CAUTION: Make a hole approximately 2 mm (0.08 inch) depth using a drill bit of 3 mm (0.12 inch) diameter.





13. Using a spanner [36 mm width across flats] or adjustable wrench, remove the holder.
14. Remove the rack bushing and rack stopper from rack assembly.
15. Remove the oil seal from rack.





16. Insert the ST from pinion housing side, and then remove the oil seal using a press.
ST 34199AE050 OIL SEAL REMOVER





17. Using a press, remove the bushing at gearbox installation portion.

CONTROL VALVE
1. Disconnect the pipes A and B from gearbox.





2. Secure the gearbox removed from the vehicle in vise using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D

CAUTION: Secure the gearbox in a vise using ST as shown. Do not attempt to secure it without this ST.





3. Using the ST, loosen the lock nut.
ST 926230000 SPANNER





4. Tighten the adjusting screw until it no longer tightens.
5. Loosen the adjusting screw, and then remove the spring and sleeve.





6. Remove the two bolts securing valve assembly.





7. Carefully draw out the input shaft, and then remove the valve assembly.





8. Wrap the tape to spline part, and slide the dust cover out.





9. Using a press remove the pinion & valve assembly from valve housing.





10. Using the ST and press, remove the bushing and oil seal from valve housing.
ST 34199AG090 INSTALLER & REMOVER

CAUTION:
^ Do not apply force to the end surface of valve housing.
^ Do not reuse the oil seal after removal.





11. Using a snap ring pliers, remove the snap ring, valve, oil seal and backup washer.

CAUTION: Be careful not to scratch the pinion & valve assembly.