Steering Rack End Removal and Installation

Steering Rack End Removal and Installation

Special Tools Required

- Attachment, 32 x 35 mm 07746-0010100
- Driver handle 07749-0010000
NOTE:

- Do not allow dust, dirt, or other foreign materials to enter the gearbox.

- Do not disassemble the steering gearbox assembly (motor). If the motor is faulty, replace it as an assembly.

Removal

1. 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.
NOTE: After removing the boot, check for water, dirt, or other foreign matter on the ball screw surface (C) and interior of the boot. If contaminated, clean the ball screw, gearbox housing, and boot completely.






2. Unbend the lock washer.






3. Hold the flat surface sections (A) on the passenger's side steering rack shaft with one wrench, and unscrew both rack ends (B) with another wrench. Be careful not to damage the shaft surface with the wrench. Remove the lock washers (C) and discard them.






4. Check the rubber stop (A) for damage or deterioration. If the rubber stop is damaged or deteriorated, replace it.
Grasp the left rack end, and pull the rack shaft all the way to the left. Carefully remove the rubber stop by prying it out of the gearbox housing (B) with a flat tip screwdriver (C) on the cut-out portion (D) so as not to damage the housing.






5. If the rubber stop was removed, position a new rubber stop (A) in the gearbox housing, then drive it in using the attachment and the driver as shown. Make sure that the attachment and the driver presses against the metal portion (B) of the rubber stop.






Installation

1. Install the new lock washer (A) on the rack shaft. Align the lock washer tabs (B) with the slots (C) in the rack shaft. Install the rack end (D) while holding the lock washer in place. Repeat this step for the other side of the rack shaft.

2. Hold the flat surface sections (E) on the steering rack shaft with one wrench, and tighten both rack ends with another wrench. Be careful not to damage the shaft surface with the wrench.






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






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

5. Apply a light coat of silicone grease to the boot grooves (B) on the rack ends.
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.






6. Center the steering rack within its stroke. Install the boots (A) in the rack end with the tie-rod clips (B). Clean off any grease or contamination from the groove around (C) on the housing.

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






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






9. Close the ear portion (A) of the band with a commercially available Oetiker 1098 pincers or equivalent (B).

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