Disassemble
TOOL REQUIRED- 07NAD-SR3020A Cylinder End Seal Remover Attachment
- 07GAF-PH70100 Pilot Collar
NOTE:
- Before disassemble the gearbox, wash it off with solvent and a brush.
- Do not dip seals and O-rings in solvent.
1. Remove the steering gearbox.
2. Remove the tie-rod end and locknut.
3. Remove air tube and clips.
4. Remove the boot bands and tie-rod clips. Pull the boots away from the ends of the gearbox.
5. Hold the steering rack with a wrench, and unscrew the rack end with another wrench.
CAUTION: Be careful not to damage the rack surface with the wrench.
6. Loosen the locknut, then remove the rack guide screw and O-ring.
7. Remove the spring and the rack guide from the gear housing.
8. Remove cylinder lines A and B from the gearbox.
9. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth.
10. Remove the two flange bolts, then remove the valve body unit from the gearbox.
11. Drill a 3 mm (0.12 inch) diameter hole approximately 2.5 - 3.0 mm (0.10 - 0.12 inch) in depth in the staked point on the cylinder.
CAUTION:
- Do not allow metal shavings to enter the cylinder housing.
- After removing the cylinder end, remove any burrs at the staked point.
12. Hold the steering gearbox using a C-clamp as shown.
13. Loosen and remove the cylinder end.
14. Assemble a 12 x 1.25 mm flange nut onto a 12 x 175 mm grade 10 flange bolt as shown.
NOTE: Wrap the flange portion of the bolt with vinyl tape to protect the cylinder.
15. Install the flange bolt into the end of the steering rack until it bottoms in the hole, then back the flange bolt out 1/4 turn. Hold the flange bolt, and tighten the flange nut against the rack by hand.
16. Install the bearing separator on the gearbox housing as shown.
17. Set the gearbox in a press so the gear housing point upward, then press the cylinder end seal and steering rack out of the gearbox.
NOTE: Hold the steering rack to keep it from falling when pressed clear.
CAUTION:
- Be careful not damage to inner surface of the cylinder housing with the flange bolt.
- Do not place your fingers under the steering rack.
18. Remove the 12 mm bolt and nut from the steering rack.
19. Remove the cylinder end seal from the steering rack.
20. Insert a 24" long, 3/8" drive extension and the special tool into the cylinder from the gearbox side.
NOTE: Make sure that the special tool is securely positioned on the backup ring edges.
CAUTION: Be careful not damage to inner surface of the cylinder housing with the special tool.
21. Set the gearbox in a press, then press out the cylinder end seal and backup ring from the gearbox.
CAUTION:
- Keep the tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it if necessary, when removing the cylinder end seal.
- Use a press to remove the cylinder end seal. Do not try to remove the seal by striking the tool. It will break the backup ring, and the cylinder end seal will remain in the gearbox.
22. Carefully pry the piston seal ring and O-ring off the piston rack.
CAUTION: Be careful not to damage the inside of seal ring groove and piston edges when removing the seal ring.
23. Before removing the valve housing, apply vinyl tape to splines of the pinion shaft.
24. Separate the valve housing from the pinion shaft/valve using a press.
25. Check the inner wall of the valve housing where the seal ring slides with your finger. If there is a step in the wall, the valve housing is worn. Replace the valve housing.
NOTE:
- There may be the sliding marks from the seal ring on the wall of the valve housing. Replace the valve housing only if the wall is stepped.
- When the valve housing is replaced, install new shim(s) on the bearing surface of the housing to adjust the thickness.
26. Check for wear, burrs and other damage to the edges of the grooves in the sleeve.
NOTE: The pinion shaft and sleeve are a precision matched set. If either the pinion shaft or sleeve must be replaced, replace both parts as a set.
27. Remove the circlip and pinion shaft sleeve from the pinion shaft.
28. Using a cutter or an equivalent tool, cut and remove the four seal rings from the sleeve.
CAUTION: Be careful not to damage the edges of the sleeve grooves and outer surface when removing the seal rings.
29. Using a cutter or an equivalent tool, cut the valve seal ring and O-ring at the groove the pinion shaft. Remove the valve seal ring and O-ring.
CAUTION: Be careful not to damage the edges of the pinion shaft groove and outer surface when removing the valve seal ring and O-ring.
30. Remove the valve oil seal and backup ring from the pinion shaft.
NOTE:
- Inspect the ball bearing by rotating the outer race slowly. If there is any excessive play, replace the pinion shaft and sleeve as an assembly.
- The pinion shaft and sleeve are a precise fit; do not intermix old and new pinion shafts and sleeves.
31. Press the valve oil seal and roller bearing out of the valve housing using a hydraulic press and special tool shown below.