Disassembly

The content of this article reflects the contents of manual update 18-130-08 dated 07/03/08.








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 unit.

2) Secure the gearbox removed from vehicle in a vise using ST.

ST1 926200000 STAND
ST2 34199AG000 BOSS D

CAUTION:
Secure the gearbox in a vise using ST as shown in the figure. Do not secure the gearbox 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 if there is damage, cracks or deterioration.





6) Using the ST, loosen the lock nut.

ST 926230000 SPANNER





7) Tighten the adjusting screw until it can no longer be tightened.





8) Remove the tie-rod.
9) Loosen the adjusting screw, and remove the spring and sleeve.
10) Remove the two bolts securing valve assembly.





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





12) Using a drill, release the crimping of holder.

CAUTION:
Make a hole of 2 mm (0.08 in) depth using a drill with 3 mm (0.12 in) diameter.





13) Remove the holder.
14) Attach the ST on the pinion housing side of rack, and press out the rack with the outer side oil seal.

ST 34199XA030 INSTALLER & REMOVER 44

NOTE:
Block the pipe connection of steering body to prevent fluid from flowing out.





15) Insert the ST from pinion housing side and remove the oil seal using a press.

ST 34199XA060 OIL SEAL REMOVER





16) Using a press, remove the bushing of gearbox installation portion.





CONTROL VALVE

1) Disconnect the pipes A and B from gearbox.
2) Secure the gearbox removed from vehicle in a vise using ST.

ST1 926200000 STAND
ST2 34199AG000 BOSS D

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





3) Using the ST, loosen the lock nut.

ST 926230000 SPANNER





4) Tighten the adjusting screw until it can no longer be tightened.





5) Loosen the adjusting screw, and remove the spring and sleeve.
6) Remove the two bolts securing valve assembly.





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





8) Put a vinyl tape around the spline portion, and slide the dust cover to remove.





9) Using a press, remove the pinion and valve assembly from valve housing.





10) Using the ST and a press, remove the bushing and oil seal from the valve housing.

ST 34199AG090 INSTALLER & REMOVER

CAUTION:
^ Do not apply a 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 back-up washer.

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