Steering Gearbox: Disassembly

Disconnect four pipes from gearbox.
NOTE: Remove pipes E and F as a single unit being fixed at the clamp plate.
Secure gearbox removed from vehicle in vice using ST.
ST 926200000 STAND

CAUTION: Secure the gearbox in a vice using the ST as shown. Do not attempt to secure it without this ST.

Fig 1: Securing Gearbox Removed From Vehicle In Vice Using ST
Remove tie-rod end and lock nut from gearbox.
Remove small clip from boot using pliers, and move boot to tie-rod end side.

Fig 2: Removing Small Clip From Boot Using Pliers
Remove boot together with large clips

Fig 3: Removing Boot Together With Large Clips
Extend rack approximately 40 mm (1.57 in) out. Unlock lock wire at lock washer on each side of tie-rod end using a standard screwdriver.
CAUTION: Be careful not to scratch rack surface as oil leaks may result.

Fig 4: Unlocking Lock Wire At Lock Washer
Using ST, loosen lock nut. ST 926230000 SPANNER

Fig 5: Loosening Lock Nut Using ST
Tighten adjusting screw until it no longer tightens.

Fig 6: Tightening Adjusting Screw
Using a wrench [32 mm (1.26 in) width across flats] or adjustable wrench, remove tie-rod.
CAUTION:
- Check ball joint for free play, and tie-rod for bends. Replace if necessary.
- Check dust seals used with tie-rod end ball joint for damage or deterioration. Replace if necessary.
Fig 7: Removing Tie-Rod Using Wrench
Loosen adjusting screw and remove spring and sleeve.
CAUTION: Replace spring and/or sleeve if damaged.
Remove two bolts securing valve assembly.

Fig 8: Removing Two Bolts Securing Valve Assembly
Carefully draw out input shaft and remove valve assembly.

Fig 9: Drawing Out Input Shaft & Removing Valve Assembly
Draw out pinion and valve assembly from valve housing, as necessary, using pipe of I.D. 44 to 46 mm (1.73 to 1.81 in) and a press.

Fig 10: Drawing Out Pinion & Valve Assembly From Valve Housing
Using a sharp pointed pliers, rotate the rack stopper in the direction of the arrow until the end of the circlip comes out of the stopper. Rotate the circlip in the opposite direction and pull it out.

Fig 11: Removing Circlip Using Sharp Pointed Pliers
Pull rack assembly from cylinder side, and draw out rack bushing and rack stopper together with rack assembly.
CAUTION: Be careful not to contact rack to inner wall of cylinder when drawing out. Any scratch on cylinder inner wall will cause oil leakage.

Fig 12: Removing Rack Assembly, Rack Bushing & Rack Stopper
Remove rack bushing and rack stopper from rack assembly.
CAUTION: Do not reuse removed rack bushing and circlip.