Steering Rack End Removal/Installation

Steering Rack End Removal and Installation

Exploded view





NOTE:

- Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.
- Refer to the Exploded View as needed during the following procedure.

Removal

1. Remove the steering gearbox.

2. Remove the tie-rod ends from the rack end.

3. Remove the boot bands (A), and discard them. Remove the tie-rod clips (B), and pull the boots away from the ends of the steering gearbox.






4. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) to a work bench as shown. Do not clamp the cylinder part of the gearbox housing in a vise.






5. Unbend the lock washers (A).






6. Hold the flat surface sections (A) of the steering rack (B) with one wrench, and unscrew both rack ends (C) with another wrench. Be careful not to damage the rack surface with the wrench.





7. Remove the lock washer (D) and the rubber stop (E).

Installation

1. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) to a work bench as shown. Do not clamp the cylinder part of the gearbox housing in a vise.






2. Install a new rubber stop (A) and a new lock washer (B). Align the lock washer tabs (C) with the slots (D) on the rack end (E) while holding the lock washer in place. Repeat this step for the other side of the rack.





3. Hold the flat surface sections of the steering rack with one wrench, and tighten both rack ends with another wrench. Be careful not to damage the rack surface with the wrench.

4. Bend the lock washer (A) back against the flat spots (B) on the rack end joint housing.






5. Apply multipurpose grease to the circumference of the rack end joint housing (A).





6. Apply a light coat of silicone grease to the boot fitting grooves (B) on the rack end.

NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.

7. Clean off any grease or contamination from the boot installation grooves (A) around the gearbox housing. Install the boots (B) on the rack ends with the tie-rod clips (C), and fit the boot end in the installation grooves in the housing properly.





8. After installing the boots, wipe the grease off the threaded section (D) of the rack end.

9. Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.






10. Close the ear position (A) of the boot band (B) with pincers Oetiker 1098, commercially available or equivalent (C).





11. Slide the steering rack right and left to be certain that the boots are not deformed or twisted.

12. Install the tie-rod end to the rack end.

13. Install the steering gearbox.