Steering Rack End Removal and Installation

Steering Rack End Removal and Installation

Exploded view





Removal

NOTE: Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.

1. Remove the tie-rod ends.

2. 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.






3. 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.






4. Unbend the lock washer (A).






5. Unscrew both rack ends (A) with a wrench. Be careful not to damage the rack shaft surface with the wrench. Remove the rack end, the lock washer (B), the spacer (C), and rubber stop (D).






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 spacer (A), rubber stop (B), and a new lock washer (C). Align the lock washer tabs (D) with the flat spots (E) on the rack end (F) ball joint housing. Install the rack end while housing the lock washer in place. Repeat this step for the other side of the rack.
NOTE: Make sure that the tapered side (G) of the rubber stop is toward the housing side.






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






4. Stake the lock washer at the stake point (A) on the rack.






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

6. Apply a light coat of silicone grease to the boot 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 on 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 portion (A) of the boot band (B) with commercially available boot band pliers, Oetiker 1098 or equivalent (C).

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

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

13. Install the steering gearbox. Steering Gearbox Removal and Installation