Overhaul

Steering Gearbox Overhaul

Exploded View





Special Tools Required

- Cylinder End Seal Remover Attachment 07TAF-SZ50100
- Pilot Collar 07GAF-PH70100
- Valve Seal Ring Sizing Tool 07NAG-SR3090A
- Ball Joint Boot Clip Guide 07974-SA50800
- Sleeve Seal Ring Sizing Tool 07974-SA5020A
- Driver Handle, 15 x 135L 07749-0010000
- Bearing Driver Attachment, 32 x 35 mm 07746-0010100
- Seal Ring Guide 07ZAG-S3VA100
- Seal Ring Sizing Tool 07ZAG-S3VA200
- Pincers Oetiker 1098, commercially available

NOTE: Refer to the Exploded View as needed during this procedure.

Disassembly

1. Remove the steering gearbox Steering Gearbox Removal.

2. Disconnect the tie-rod ends. Remove the boot bands (A) and tie-rod clips (B). Pull the boots away from the ends of the steering gearbox.






3. Unbend the lock washer (A).






4. Hold the flat surface sections (A) of the steering rack (B) with a wrench, and unscrew both rack ends (C) with another wrench. Be careful not to damage the rack surface with the wrench. Remove the lock washer (D) and stop rubber (E).






5. Loosen the locknut (A), then remove the rack guide screw (B).





6. Remove the spring (C) and the rack guide (D) from the gearbox housing.

7. Remove the cylinder line A and B from the steering gearbox.





8. Drain the fluid from the cylinder fittings by slowly moving the steering rack back and forth.

9. Remove the return line joint (A).





10. Remove the two flange bolts, then remove the valve body unit (B) from the gearbox housing (C). Remove the O-ring (D).

11. Apply vinyl tape (A) to the end of the steering rack and the gearbox housing. Drill a 3 mm (0.12 in) diameter hole about 2.5-3.0 mm (0.10-0.12 in) in depth in the staked point (B) on the cylinder. Do not allow metal shavings to enter the gearbox housing. After removing the cylinder end (C), remove any burrs at the staked point.

NOTE: Apply vinyl tape (D) to the drill, and do not drill the depth more than necessary.






12. Attach the yoke of a universal puller (commercially available) (A) to the steering gearbox mounts with bolts. Clamp the yoke in a vise with soft jaws as shown. Do not clamp the cylinder part of the gearbox housing in a vise. Remove the vinyl tape. then loosen and remove the cylinder end (B).






13. Install a commercially available bearing separator (A) on the gearbox housing as shown.





14. Place an appropriate size deep socket (B) on the steering rack (C).

15. Set the steering gearbox in a press so the gearbox housing side points upward, then press the cylinder end seal (D) and steering rack out of the steering gearbox. Hold the steering rack to keep it from falling when pressed clear. Be careful not to damage the inner surface of the cylinder side on the gearbox housing with the tool.

16. Remove the cylinder end seal from the steering rack.

17. Carefully pry the piston seal ring (A) and O-ring (B) off the rack piston. Be careful not to damage the inside of the seal ring groove and piston edges when removing the seal ring.






18. Install a washer (O.D. 27.5 mm, P/N 94103-10400) (A) so it fits through the rack guide hole of the gearbox housing, then position the washer on the backup ring (B). Make sure that the washer is centered on the backup ring.






19. Install the socket with a 27.5 mm O.D. (A) onto the 24'' long 3/8'' drive extension (B), and carefully place it on the washer (C).





20. Set the steering gearbox in a press so the gearbox housing points upward, then push the backup ring and the cylinder end seal (D) for 5-6 mm (0.20-0.24 in) by pressing on the 24'' long 3/8'' drive extension end.

21. Remove the steering gearbox from the press, and remove the washer from inside the gearbox housing.

22. Turn the cylinder end seal remover attachment (A) so it fits through the rack guide hole of the gearbox housing, then position the cylinder end seal remover attachment on the backup ring (B). Make sure that the cylinder end seal remover attachment is securely positioned on the backup ring.






23. Insert a 24'' long 3/8'' drive extension (A), on the cylinder end seal remover attachment (B). Place the gearbox housing in a press, then remove the backup ring (C) and the cylinder end seal (D) from the gearbox housing by pressing on the 24'' long 3/8'' drive extension.

Note these items when pressing the backup ring and cylinder end seal:

- Keep the tool straight to avoid damaging the cylinder wall. Check the tool angle, and correct it if necessary, when removing the backup ring and the cylinder end seal.
- Use a press to remove the backup ring and the cylinder end seal. Do not try to remove the backup ring and the cylinder end seal by striking the tool; striking the tool would break the backup ring and the cylinder end seal, and the backup ring and the cylinder end seal would remain in the gearbox housing.





24. Apply vinyl tape (A) to the splines on the pinion shaft (B).





25. Separate the valve housing (C) from the pinion shaft/valve using a press.

26. With your finger, check the inner wall of the valve housing where the seal ring slides. If there is a step in the wall, the housing is worn, replace it.

NOTE: There may be sliding marks from the seal ring on the wall of the valve housing. Replace the valve housing only if the wall is stepped.






27. 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.






28. Remove the snap ring (A) and sleeve (B) from the pinion shaft (C).






29. Using a cutter or an equivalent tool, cut and remove the four seal rings (A) from the sleeve. Be careful not to damage the edges of the sleeve grooves and outer surface when removing the seal rings.






30. Using a cutter or an equivalent tool, cut the valve seal ring (A) and O-ring (B) at the cutting groove position (C) in the pinion shaft. Remove the valve seal ring and O-ring. Be careful not to damage the edges of the pinion shaft groove and outer surface when removing the valve seal ring and O-ring.






31. Remove the valve oil seal (A) and wave washer (B) from the pinion shaft.

Note these items during disassembly:

- Inspect the ball bearing (C) by rotating the outer race slowly. If there is any excessive play or wear, replace the pinion shaft and sleeve as an assembly.
- The pinion shaft and sleeve are a precise fit; do not intermix with old and new pinion shafts and sleeves.





32. Remove the valve oil seal (A) and roller bearing (B) out of the valve housing with a hydraulic press and pilot collar (C).





33. Clean the disassembled parts with solvent, and dry them with compressed air. Do not dip rubber parts in the solvent.

Reassembly

34. Apply vinyl tape (A) to the stepped portion of the pinion shaft, and coat the surface of the vinyl tape with power steering fluid.





35. Install the wave washer (B).

36. Coat the inside surface of a new valve oil seal (C) with power steering fluid, and install the seal with its grooved side facing opposite the bearing, then slide it over the pinion shaft, being careful not to damage its sealing lip (D). Remove the vinyl tape.

37. Apply vinyl tape (A) to the splines and stepped portion of the shaft, and coat the surface of the vinyl tape with power steering fluid.





38. Fit a new O-ring (B) in the groove of the pinion shaft. Then slide a new valve seal ring (C) over the shaft and in the groove on the pinion shaft.

39. Remove the vinyl tape, and apply power steering fluid to the surface of the valve seal ring (A).





40. Apply power steering fluid to the inside of the valve seal ring sizing tool (B). Set the larger diameter end of the sizing tool over the valve seal ring, and move the sizing tool up and down several times to make the valve seal ring fit in the pinion shaft groove.

41. Remove the sizing tool, turn it over, slide the smaller diameter end over the valve seal ring. Move it up and down several times to make the valve seal ring fits snugly in the pinion shaft groove.

42. Apply power steering fluid to the surface of the ball joint boot clip guide (A). Slip two new seal rings (B) over the ball joint boot clip guide from the smaller diameter end, and expand them. Install only two rings at a time from each end of the pinion shaft sleeve (C).

Note these items when installing the seal ring:

- Do not over-expand the seal ring. Install the resin seal rings with care so as not to damage them. After installation, make sure you contract the seal rings using the sizing tool.
- There are two types of sleeve seal rings; black and brown. Do not mix the different types of rings as they are not compatible.





43. Align the ball joint boot clip guide with each groove in the sleeve, and slide a sleeve seal ring into each groove. After installation, compress the seal rings with your fingers temporarily.

44. Apply power steering fluid to the seal rings on the sleeve, and to the entire inside surface of the sizing tool, then slowly insert the sleeve into the sizing tool.





45. Move the sleeve back and forth several times to make sure the seal rings fit snugly in the sleeve. Make sure the seal rings are not twisted and contract the seal rings.

46. Apply power steering fluid to the surface of the pinion shaft (A). Slide the sleeve (B) onto the pinion shaft by aligning the locating pin (C) on the pinion shaft with the cutout (D) in the sleeve. Then install a new snap ring (E) securely in the pinion shaft groove. Be careful not to damage the valve seal ring when inserting the sleeve.






47. Apply power steering fluid to the seal ring lip of a new valve oil seal (A), then install the seal in the valve housing (B) with the 15 x 135L driver handle (C), the 32 x 35 mm attachment (D), and a hydraulic press. Install the seal with its grooved side facing the tool.





48. Press the roller bearing (E) into the valve housing with the driver handle, the 32 x 35 mm attachment and a hydraulic press.

49. Apply vinyl tape (A) to the pinion shaft/sleeve (B), then coat the vinyl tape with power steering fluid.





50. Insert the pinion shaft/sleeve into the valve housing (C). Be careful not to damage the valve seal rings (D).

51. Remove the vinyl tape from the pinion shaft, then remove any residue from the tape adhesive.

52. Press the pinion shaft/sleeve into the valve housing with a hydraulic press. Check that the pinion shaft/sleeve turns smoothly by hand after installing it.





53. Coat the piston seal ring guide with power steering fluid, then slide it onto the rack, big end first.

54. Position a new O-ring (A) and a new piston seal ring (B) on the seal ring guide (C), then slide them down toward the big end of the tool.

Note these items during reassembly:

- Do not over expand the resin seal rings. Install the resin seal rings with care so as not to damage them. After installation, make sure you contract the seal ring using the sizing tool.
- Replace piston's O-ring and seal ring as a set.





55. Pull the O-ring off into the piston groove, then pull the piston seal ring off into the piston groove on top of the O-ring.

56. Coat the piston seal ring (A) and the inside of the seal ring sizing tool (B) with power steering fluid, then carefully slide the tool onto the rack and over the piston seal ring.





57. Move the sizing tool back and forth several times to make the piston seal ring fits snugly in the piston.

58. Wrap vinyl tape (A) around the rack teeth and rack end edges, then coat the surface of the tape with power steering fluid. Make sure that the vinyl tape is wrapped carefully so there is no stepped portion.






59. Coat the inside surface of a new cylinder end seal (A) with power steering fluid, then install it onto the steering rack with its grooved side toward the piston. When installing the cylinder end seal, be careful not to damage the lip of the seal with the edges or teeth of the steering rack.





60. Remove the vinyl tape from the steering rack, then remove any adhesive residue.

61. Install a new backup ring (A) on the steering rack, then place the backup ring and cylinder end seal (B) against the piston (C).






62. Apply steering grease to the steering rack teeth, then insert the steering rack into the gearbox housing. Be careful not to damage the inner surface of the cylinder wall with the rack edges.






63. Insert an appropriate size deep socket (A) onto the steering rack as shown.





64. Install the backup ring (B) and the cylinder end seal (C) into the bottom of the cylinder by pressing on the tool with a press. Do not push on the tool with excessive force as it may damage the backup ring and cylinder end seal.

65. Remove the tool, and center the steering rack.

66. Wrap vinyl tape around the rack end edges, and coat the surface of the tape with the power steering fluid. Make sure that the vinyl tape is wrapped carefully so there is no stepped portion.






67. Coat the inside surface of a new cylinder end seal (A) and steering rack with power steering fluid, then install the cylinder end seal onto the steering rack with its grooved side toward the cylinder.





68. Push in the cylinder end seal with your finger. Be careful not to damage the face of the seal with the threads and burrs at the staked position of the cylinder housing.

69. Remove the vinyl tape from the steering rack, then remove any adhesive residue.

70. Attach the yoke of a universal puller (commercially available) (A) to the steering gearbox mounts with bolts, then clamp the yoke in a vise with soft jaws. Do not clamp the cylinder part of the gearbox housing in the vise.






71. Coat the inside surface of the cylinder end (A) with power steering fluid, then install the cylinder end by screwing it into the cylinder (B).





72. Tighten the cylinder end (C) to the specified torque, then stake the point of the cylinder as shown (opposite from where the stake was removed during disassembly). Remove the yoke from the gearbox.

73. Coat a new O-ring (A) with steering grease, and carefully fit it on the valve housing.





74. Apply steering grease to the needle bearing (B) in the gearbox housing, then install the valve body unit (C) by engaging the gears. Note the valve body unit installation position (direction of the line connections).

75. Tighten the flange bolts (D) to the specified torque.

76. Install the return line joint (E), and tighten to the specified torque.

77. Install the cylinder line A and B to the steering gearbox.

Note these items during reassembly:

- Thoroughly clean the joints of the cylinder lines. The joints must be free of foreign material.
- Install the cylinder lines by tightening the flare nuts by hand first, then tighten the flare nuts to the specified torque.





78. Apply steering grease to the sliding surface of the rack guide (A), and install it onto the gearbox housing.





79. Remove the old sealant from the rack guide screw (B), then apply new sealant (Three Bond 1215 or Loctite 5699) to the middle of the threads. Install the spring (C), rack guide screw and locknut (D).

NOTE: If more than 5 minutes has passed after applying the sealant, remove the old sealant and residue, and reapply new sealant.

80. Adjust the rack guide screw Adjustments. After adjusting, check that the rack moves smoothly by sliding it right and left.

81. Install a new stop rubber (A) and a new lock washer (B) on the rack end (C) in the rack. Align the lock washer tabs (D) with the slots (E). Install the rack end (F) while holding the lock washer in place. Repeat this step for the other side of the rack.





82. Hold the flat surface sections (G) of the steering rack with one wrench, and tighten both rack ends with another wrench. Be careful not to damage the rack surface with the wrench.

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






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





85. Apply a light coat of silicone grease (P/N 08798-9013) 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.

86. Center the steering rack within its stroke.

87. Clean off any grease or contamination from the boot installation grooves (A) around 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.





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

89. Install new boot bands (A) by aligning the tabs (B) with the holes (C) on the band.






90. Close the ear portion (A) of the boot band (B) with Oetiker 1098 pincers or equivalent (C).





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

92. Install the tie-rod end to the rack end.

93. Install the steering gearbox Steering Gearbox Installation.