Rack and Pinion Disassembly and Assembly

Rack and Pinion

Disassembly

Tools Required:
KM-1-22610 Installer

1. Remove the rack and pinion steering assembly from the vehicle.
2. Remove the valve and pinion assembly from the rack and pinion steering assembly.
3. Remove the rack bearing assembly from the rack and pinion steering assembly.
4. Mark the threads on the inner tie rod to aid in repositioning the adjusting nut.





5. Loosen the adjusting nut and remove the outer tie rod nut and the adjusting nut.





6. Remove the dust boot retaining clamps and remove the dust boot.





7. Remove the inner tie rod.





8. Remove the adjuster plug lock nut, adjuster plug, adjuster spring and rack bearing.





9. Remove the dust cover, snap ring and pinion lock nut. The pinion lock nut can be removed when the pinion shaft is fixed.





10. Remove the dust cover (Rubber) and snap ring.





11. Remove the pinion gear and valve assembly by tapping on the pinion shaft gently with a hammer and steel bar.





12. Remove the pinion shaft seal and middle bearing.





13. Remove the pinion shaft ball bearing by tapping on the pinion shaft gently with a rubber hammer and steel bar.





14. To remove the steering rack gear, remove the circlip from the rack gear housing.





15. Pull out the rack gear and rack gear stopper at the same time from the rack gear housing.


Assembly
1. Install the rack gear and rack gear stopper to the rack gear housing.





2. Install the circlip.





3. Install the pinion shaft ball bearing.





4. Install the pinion shaft, seal and needle bearing.





5. Install the snap ring and dust cover (Rubber).





6. Install the pinion lock nut, snap ring and dust cover.
Tighten: Tighten the pinion lock nut to 30 Nm (22 ft. lbs.).
7. Coat the rack bearing, the adjuster spring, and the adjuster plug with lithium-based grease and install them into the housing.
8. With the rack centered, turn the adjuster plug clockwise until a torque of 7 Nm (62 inch lbs.) is obtained, then back it off by 30 to 40°. Check the pinion torque. Maximum pinion preloaded torque is 1 Nm (9 inch lbs.).





9. Thread the locknut on the adjuster plug and tighten it.
Tighten: Tighten the adjuster plug locknut to 75 Nm (56 ft. lbs.) while holding the adjuster plug stationary with the rack guide spring cap wrench 3-42459 or with a 19 mm allen wrench.





10. Install the inner tie rod.
Tighten: Tighten the inner tie rod to 100 Nm (74 ft. lbs.).





11. Install the dust boot and retaining clamps.





12. Install the outer tie rod end and lock nut.
Tighten: Tighten the outer tie rod end lock nut to 64 Nm (47 ft. lbs.).