Steering Gear Disassembly

1. Remove steering gear.
2. Wash gearbox off with solvent and brush. Do not dip seals and O-rings in solvent.
3. Remove air hose and clips, then the tie-rod end locknut.
4. Remove boot bands and tube clamps, then pull boots away from ends of gearbox.

Fig. 13 Exploded View Of Power Steering Gear:

5. Unbend lock washer, then hold steering rack, Fig. 13, with wrench and unscrew rack end with wrench.
6. Loosen locknut and remove rack guide screw.
7. Remove spring and rack guide from gear housing, then the cylinder pipes A and B from gearbox.
8. Drain fluid from cylinder fittings by slowly moving steering rack back and forth.
9. Remove two flange bolts, then the valve body unit from gearbox.
10. Drill 0.12 inch diameter hole approximately 0.12 inch in depth into staked point on cylinder. Do not allow metal shavings to enter cylinder housing. After removing cylinder end, remove any burrs at staked point.
11. Install suitable puller yoke on steering gearbox, then clamp yoke in vise and loosen and remove cylinder end.
12. Set gearbox in press so gear housing points upward, then assemble 12 x 1.25 mm flange nut onto 12 x 170 mm grade 170 flange bolts. Wrap flange portion of bolt with vinyl tape to protect cylinder.
13. Install flange bolt into end of steering rack until it bottoms in hole, then back flange bolt out 1/4 turn. Hold flange bolt and tighten flange nut against rack by hand.
14. Press cylinder end seal and steering rack out of gearbox. Hold steering rack to keep it from falling when pressed clear.
15. Remove 12 mm bolt and nut from steering rack, then the cylinder end seal from steering rack.

Fig. 14 Back-up Ring Removal:

16. Remove cylinder end seal and back-up ring from gearbox as follows:
a. Insert 24 inch long, 3/8 inch drive extension and cylinder end seal remover attachment tool No. 07NAD-SR30200, or equivalent, into cylinder from gearbox side, Fig. 14.
b. Set gearbox in press, then press out cylinder end seal and back-up ring from gearbox. Keep tool straight to avoid damaging cylinder wall. Check tool angle and correct it if necessary when removing cylinder end seal. Do not try to remove seal by striking remover tool. It will break the back-up ring and the cylinder end seal will remain in gearbox.
17. Carefully pry piston seal ring and O-ring off piston of rack.