Overhaul

TOOL REQUIRED
- 07746-0020100 Driver, 22 mm I.D.
- Roll Pin Drift

DISASSEMBLE
1. Place the gearbox in a vise with a soft jaws, then clamp the gearbox at the mount bracket or gear housing.

CAUTION: Be careful not to distort the gear housing by clamping it too tight in the vise incorrectly.

2. Remove the tie-rod end and locknut.





3. Remove the boot bands and tie-rod clips. Pull the boots away from the ends of the gearbox.





4. Hold the steering rack with one wrench, and unscrew the rack end with another wrench.

CAUTION: Be careful not to damage the rack surface with the wrench.

5. Push the right end of the rack back into the cylinder housing so the smooth surface that rides against the seal won't be damaged.
6. Loosen the locknut, and remove the rack guide screw.





7. Remove the disc washer, spring and rack guide from the gear housing.
8. Remove the pinion dust seal and the 35 mm snap ring.





9. Hold the pinion shaft with a vise securely. Remove the pinion by tapping evenly around the flanged section of the gearbox with a plastic hammer.

CAUTION: Do not tap on the steering rack.

NOTE: Do not reuse the removed pinion.





10. Slide the steering rack out of the cylinder housing.

CAUTION: Be careful not to damage the bushing in the cylinder housing.





11. Remove the rack end bushing.





12. Replace the gearbox mounting cushion if necessary:
a. To remove the cushion, use a sharp knife and make a cut down the length of the cushion. Be careful not to damage the paint on the outside of the cylinder housing. Remove the old cushion.
b. Apply weatherstrip adhesive to the inside of the new cushion. Install the cushion onto the cylinder housing and position it 20 - 22 mm (0.79 - 0.87 inch) from the end of the cylinder housing as shown.

NOTE: After installing the cushion, wipe off any excess adhesive that may have dripped into the inside of the cylinder housing.





ASSEMBLE

NOTE:
- Clean the disassembled parts with solvent, and dry them with compressed air. Do not dip the rubber parts in solvent.
- Always replace the non-reuseable parts with new ones before assembly.
- Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.

1. Apply a thin coat of grease to the inside surface of the rack end bushing. Grease quantity: 1 - 3g (0.04 - 0.1 oz).

CAUTION: Do not fill the slots with grease; they must remain open to serve as air passages.





2. Install the rack end bushing by aligning the round projection on the bushing with the hole in the cylinder housing
3. Grease the steering rack teeth.





4. Install the steering rack into the cylinder housing carefully to avoid damaging the rack end bushing.





5. Drive in the steering pinion in the gear housing with the special tools.
6. Install the 35 mm snap ring securely in the gear housing groove.
7. Apply vinyl tape to the pinion shaft, then coat the vinyl tape with grease.
8. Install the pinion dust seal on the gear housing until it seats properly, then remove the tape.
9. Grease the sliding surface of the rack guide, and install it on to the gear housing.





10. Install the spring, disc washer and rack guide screw on the gear housing.

NOTE: Install the disc washer with its convex side facing in.

11. Adjust the rack guide screw.
12. Install the new lock washer in the groove in the steering rack.





13. Install the steering rack end into the rack.
14. Hold the steering rack with a wrench and tighten the rack end with another.

CAUTION: Be careful not to damage the rack surface with the wrench.





15. After tightening the rack ends, stake the four sections of the lock washer with a roll pin drift and a mallet.
a. Place the wood block on the press table, then set the lock washer section of the rack end on the wood block securely. Be sure the tool is aligned with the flat sections of the steering rack end before pressing.
b. Stake the lock washer in the center of the flat section of the steering rack end.





16. Apply grease to the circumference of the rack end housing.
17. Apply a light coat of silicone grease to the boot grooves on the rack ends.





18. Install the boots in the rack end with the tie-rod clips.

NOTE: Install the boot band with the rack in the straight ahead position (right and led tie-rods are equal in length).

19. Install the boot band so that the locking tabs of the band (stake points) are in the range shown below. (Tabs should face up and slightly forward.)
20. Bend both sets of locking tabs.





21. Lightly tap on the doubled-over portions to reduce their height.

CAUTION: Stake the band locking tabs firmly.





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