Disassembly

Steering Gearbox

DISASSEMBLY

1) Disconnect the four pipes from steering body and control valve housing.





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

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

PREPARATION TOOL:
ST1: STAND (926200000)
ST2: BOSS D (34199AG000)

(1) Replace BOSS of STAND (ST1) with BOSS D (ST2).
(2) Using the clamp (a) removed from vehicle body, attach the gearbox assembly to ST.





3) Remove the left and right boots from the gearbox.
(1) Remove the tie-rod end and lock nut (a) from gearbox.
(2) Remove the clip (b) located outside the boot using the pliers, and then slide the boot to the tie-rod end side.





(3) Using a flat tip screwdriver, remove the band from boot.

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





4) Remove the left and right tie-rods.
(1) Using the ST, loosen the lock nut.

PREPARATION TOOL:
ST: SPECIAL TOOL CPS (34199AJ060)

(2) Tighten the adjusting screw (a) until it can no longer be tightened.





(3) Remove the tie-rod.





5) Remove the control valve.
(1) Loosen the adjusting screw (a), and remove the spring (b) and sleeve (c).





(2) Clean any dirt adhered to the input shaft.
(3) Remove the dust cover (a).

CAUTION:
^ Pay attention not to scratch the housing or input shaft and not to allow foreign matter to enter gearbox interior.
^ Roll a vinyl tape around the input shaft spline to avoid scratching the dust cover.





(4) Align the ST pin with plug hole to install, and then rotate the ST counterclockwise to remove plug (b).

PREPARATION TOOL:
ST: PLUG-WRENCH (34199AE090)





(5) Remove the valve assembly (c).

CAUTION:
Be careful not to scratch the seal rings (d) and inner surface of the valve housing.





6) Remove the rack.
(1) Remove the holder (a).





(2) Attach the ST1 to the pinion housing side of the rack.
(3) Push the rack so that the rack piston (b) pushes out the outer side oil seal (a) to be removed.

PREPARATION TOOL:
ST1: INSTALLER & REMOVER (34199FE000)





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

(4) Insert the ST2 from the valve side of the rack, and push out the back-up ring (c) and oil seal (d).

PREPARATION TOOL:
ST2: REMOVER (34199FE010)





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

7) Repair the crimped portion of cylinder.
(1) Using ST, repair the crimped portion of cylinder (a).

PREPARATION TOOL:
ST1: PUNCH (34099FA080)
ST2: BASE (34199FE020)





(2) If the cylinder edge is deformed in a convex shape, repair using an oil stone.





8) Using the ST, press the oil seal (a) out of plug.

CAUTION:
Do not apply force on the plug edge surface.

PREPARATION TOOL:
ST: OIL SEAL PLUG REMOVER (34199AE100)





9) Remove the oil seal from the valve housing.
(1) Set the ST at a size shown in the figure.

PREPARATION TOOL:
ST: GEARBOX OIL SEAL REMOVER (34199AE120)





(2) Set the stopper (b) to gearbox, then insert the tip of the ST to the gearbox.





(3) By fixing section (A), press-in the rod (c) while rotating it and catch the oil seal (a).
(4) While fixing section (A), pull out the oil seal (a) by rotating nut (d).

CAUTION:
Take care not to scratch the gearbox inner surface.