Steering gear disassembled
Note: When disassembling, please refer to the exploded view image.
Disassembly
1. Remove the steering gear (see section "Removal the steering gear").
2. Disconnect the cylinder tubes (A) and the outlet tube fitting (B) from the steering gear.
3. Drain the fluid from the cylinder nipples by slowly moving the steering rack forward and backward.
4. Bend the lock washer (A).
5. Secure the bracket (A) with one key and unscrew both rack ends (B) with another key. Remove the lock washers.
6. Remove the lock washer (A), 12mm flange bolts (B), O-rings (C) and bracket (D) from the steering gear.
7. Remove the guard (A) from the boot by unscrewing the 8 mm flange bolt (B) from the end of the steering rack.
8. Remove the clamp (C) from the boot and the clamp (D). Remove the boot (E) from the end of the steering gear. Remove the plug (F) from the end of the rack.
9. Loosen the lock nut (A), then remove the rack guide screw (B), remove the spring (C) and rack guide (D) from the steering gear.
10. Remove the ring clamp (A) and protective ring (B) from the cylinder body.
11. Remove the valve body (A) from the steering gear. Remove the O-ring (B) and discard it.
12. Remove both clamps (B) from boot A. Compress boot A with your hand and wrap it with vinyl tape (C) so that the boots are fixed in the compressed position.
13. Fix the steering gear housing in a clamp (available for sale) (A), placing wooden blocks (B) as shown in the figure. Do not clamp the cylinder body or steering gear housing in a vice.
14. Place the special tool (A) on the lock screw (B), then loosen and remove the lock screw from inside the steering gear housing (C).
15. Remove the special tool.
16. Pull the cylinder and remove it from the steering gear housing. Remove boot B and remove slide guide (B) from cylinder.
17. Check the slide guide for damage or cracks. Measure the thickness of the slide guide using a caliper. If the thickness is less than the specified limit, replace the slide guide.
18. Remove and discard the snap ring (A) from the cylinder by spreading its ends with snap ring pliers. Loosen and discard the locking screw (B).
19. Secure the cylinder body (A) in a press with the cylinder side facing down, then press the cylinder end seal (B) and rack (C) out of the cylinder. After pressing the rack out of the cylinder, hold it so that it does not fall.
20. Remove the cylinder end seal from the steering rack.
21. Insert the special tool into the cylinder. Make sure that the special tool (A) fits securely onto the edges of the bushing (B).
22. Secure the cylinder in a press, then press out the cylinder end seal (C), protective ring (D) and bushing (B) from the cylinder using a special tool.
Press out the cylinder end seal taking into account the following:
- To avoid damaging the cylinder walls, hold the special tool vertically. When removing the cylinder end seal, check the angle of the special tool and adjust it if necessary.
- Remove the cylinder end seal using a press. Do not attempt to remove the seal by striking the special tool. You will break the cylinder end seal and it will remain in the cylinder.
23. Carefully pry up the piston sealing ring (A) and O-ring (B) and remove them from the rack piston. When removing the seal ring, be careful not to damage the inside of the seal ring groove or the piston edges.
24. Before removing the valve body (A), wrap the worm shaft splines with vinyl tape (B).
25. Press the valve body out of the worm/valve shaft.
26. Check the inner wall in the valve body where the sealing ring slides by inserting your finger. If there is a ledge in the wall, the valve body is worn. Replace valve body.
Note: There may be marks on the valve body wall from the sliding of the sealing ring. Replace the valve body only if there is a ledge in the wall.
27. Check the edges of the grooves in the liner for wear, burrs or other damage.
Note: The worm shaft and sleeve are fitted to each other with a high degree of precision. If replacing either the worm shaft or the sleeve, replace them as an assembly.
28. Remove the ring clamp (A) and sleeve (B) from the worm shaft.
29. Using a cutter or similar tool, cut and remove the four sealing rings from the sleeve. When removing the sealing rings, do not damage the edges of the sleeve grooves and the outer surface.
30. Using a cutter or similar tool, cut off the valve seal ring (A) and the O-ring (B) in the groove (C) on the worm shaft. Remove the valve seal and O-ring. When removing the valve seal ring and O-ring, be careful not to damage the groove edges on the worm shaft and the outer surface.
31. Remove the valve seal (A) and wave washer (B) from the worm shaft.
Perform disassembly taking into account the following:
- Check the ball bearing (C) by slowly turning the outer ring. If there is excessive play, replace the worm shaft and sleeve assembly.
- The worm shaft and sleeve are fitted to each other with a high degree of precision; do not mix old and new worm shafts and sleeves.
32. Press the valve seal (A) and roller bearing (B) out of the valve body using a hydraulic press and a special tool.
Assembly
33. Wrap the stepped portion of the worm shaft with vinyl tape (A) and apply power steering fluid over the vinyl tape.
34. Install the wave washer (B). Apply power steering fluid to the inside surface of the new valve seal (C) and slide the seal onto the worm shaft without damaging the sealing lip (D). Install the valve seal with the groove facing away from the bearing.
35. Place the special tool on the worm and apply power steering fluid to the surface of the special tool. Place a new O-ring (A) and a new valve seal ring (B) on the special tool and expand them.
36. Insert the O-ring onto the shaft and into the groove on the worm shaft. Then place the valve seal ring onto the shaft and into the groove on the worm shaft.
37. Remove the special tool and apply power steering fluid to the surface of the valve seal ring (A).
38. Apply power steering fluid to the inside surface of the special tool. Place the larger end of the special tool on the valve seal and move the special tool up and down several times until the valve seal fits into the groove on the worm shaft.
39. Remove the special tool, turn it over and install it with the smaller diameter end on the valve sealing ring. Move the special tool up and down several times until the valve sealing ring fits tightly into the groove on the worm shaft.
40. Apply power steering fluid to the surface of the special tool. Place two new sealing rings (A) on the special tool from the smaller diameter side and expand the sealing rings. Install only two seal rings at a time on each end of the worm shaft sleeve (B).
Install the sealing rings taking into account the following:
- Do not expand the sealing ring excessively. Place the rings carefully to avoid damaging them. After putting on, squeeze the sealing rings using (calibration) special tool.
- There are two types of sleeve sealing rings: black and brown. Do not mix different types of liner seals as they are not interchangeable.
41. Align the special tool with the grooves on the sleeve and securely place the sealing rings into the grooves. After installation, temporarily squeeze the sealing rings with your fingers.
42. Apply power steering fluid to the sealing rings on the sleeve and to the entire inside surface of the special tool, then slowly insert the sleeve into the special tool.
43. Move the sleeve back and forth several times and make sure that the sealing rings are tightly seated in the sleeve. Make sure the sealing rings are not twisted.
44. Apply power steering fluid to the surface of the worm shaft (A). Place the sleeve (B) on the worm shaft, aligning the reference pin (C) on the inside of the sleeve with the notch (D) on the shaft. Then securely place the new ring clip (E) in the groove on the worm shaft. When installing the sleeve, do not damage the valve sealing ring.
45. Apply power steering fluid to the lip of the new valve seal (A), then press the seal into the valve body (B) using a hydraulic press and special tool. Press the valve seal with the groove towards the special tool.
46. Press the new roller bearing (C) into the valve body using a hydraulic press and special tool.
47. Wrap the worm shaft with vinyl tape (A), then apply power steering fluid over the vinyl tape.
48. Insert the worm shaft into the valve body (B). Be careful not to damage the valve sealing rings (C) and the sealing lip of the valve seal (D).
49. Remove the vinyl tape from the worm shaft, then remove the remaining adhesive layer of the tape.
50. Press the worm shaft/sleeve into the valve body using a hydraulic press. Make sure that after pressing, the worm shaft/sleeve turns smoothly by hand.
51. Apply power steering fluid to the special tool, then place it on the rack with the large end first.
52. Place a new O-ring (A) and a new piston seal ring (B) on the special tool and push them onto the special tool towards the large end.
Perform the assembly taking into account the following:
- Do not over-expand the sealing rings. Place the rings carefully to avoid damaging them. After putting on, squeeze the sealing rings using (calibration) special tool.
- Replace the O-ring and piston seal ring assembly.
53. Pull the O-ring into the piston groove, then pull the piston seal ring into the piston groove on top of the O-ring.
54. Apply power steering fluid to the piston seal ring (A) and the inside surface of the special tool, then carefully install the special tool onto the rack and onto the piston seal ring.
55. Move the special tool back and forth several times until the valve sealing ring fits tightly into the piston.
56. Place a new bushing (A) on the special tool and insert the special tool into the cylinder body (B).
57. Secure the cylinder in a press and press the bushing (A) into the bottom of the cylinder, applying the force of the press to the special tool. Do not exceed the seating force, as this may damage the new bushing.
58. Apply power steering fluid to the inside surface of the special tool (A) and the new cylinder end seal (B). Place the cylinder end seal onto the special tool with the groove (C) facing away from the special tool.
59. Apply a thin layer of grease to the inside surface of the special tool.
60. Place the cylinder end seal (A) onto the steering rack (B) with the groove (C) facing the piston (D). Make sure that the gap in the special tool faces away from the rack teeth.
61. Separate the cylinder end seal from the special tool, then remove the special tool.
62. Place a new protective ring (A) on the steering rack, then press the protective ring and cylinder end seal (B) onto the piston (C).
63. Apply a mark (A) to the steering rack using a felt-tip pen at a distance of 7.7 mm from the end edges of the rack.
64. Lubricate the steering rack teeth, then insert the rack (A) into the cylinder (B). Do not damage the inner surface of the cylinder walls and the bushing with the edges of the rack.
65. Secure the cylinder (A) in a press and press the cylinder end seal (B) into the bottom of the cylinder until the mark (C) on the rack reaches the edges (D) of the cylinder.
66. Apply power steering fluid to the inside and outside surfaces of the new cylinder end seal (A).
67. Place the cylinder end seal on the steering rack (B) with the groove (C) towards the piston. Push the cylinder end seal in with your finger.
68. Place the protective ring (D) on the cylinder end seal with the flat side facing up. Then press the protective ring using a socket of the appropriate size until its surface is below the groove (E) for the ring clamp. Insert the ring clamp (F) into the groove.
69. Screw the new lock screw (A) onto the cylinder.
70. Place the new snap ring (B) into the groove (C) on the cylinder, spreading its ends apart using snap ring pliers. Do not scratch or damage the cylinder surface with the edges of the retaining ring.
71. Apply general purpose grease to the housing surface as shown in the figure.
72. Insert new clamps (B) into the clamp grooves of boot A, aligning the tongues (C) with the slots (D) in the tape. Do not crimp the U-shaped part of the clamp tape yet.
73. Compress cover A with your hand and wrap it with vinyl tape (E) so that the covers are fixed in the compressed position. Pull boot A along the cylinder so that the end of the boot with the smaller diameter is positioned opposite the steering gear housing.
74. Apply universal grease to the sliding surface of the slider guide (A). Avoid getting grease on the contact surfaces "rack-slider guide" and "boot-slider guide".
Move the steering rack to the left and place the slider guide on the rack, aligning the bolt holes (B).
75. Fix the steering gear housing in the clamp (A), placing wooden blocks (B) as shown in the figure.
76. Insert the cylinder (A) into the steering gear housing (B) so that the cutout (C) aligns with the pin (D) inside the steering gear housing.
77. First tighten the lock screw (A) by hand, then place the special tool (B) on the lock screw. Tighten the lock screw slightly. Do not tighten it to the required torque yet.
78. Remove the special tool.
79. Apply grease to the new O-ring (A) and carefully insert it into the valve body.
80. Apply grease to the needle bearing (B) in the steering gear housing, then install the valve body (C), engaging the gears. Observe the installation position of the valve body (direction of tube connection). Tighten the flange bolts (D) to the specified torque.
81. Lubricate the sliding surface and circumference of the guide rack (A) and insert it into the steering gear housing. Remove grease from the threaded area of the crankcase.
82. Insert the spring (B). Apply sealant to the middle threads of the guide rack screw (C), then screw it in and tighten it to 25 Nm (2.5 kgf·m). Fit the lock nut (D).
83. Center the steering rack within its travel and align the slider guide (B) with the holes (C) in boot A. Insert the slider guide into boot A, firmly crimping the edges of the holes.
84. Before installing the bracket (D), clean the contact surfaces of the 12 mm flange bolts (E) and the bracket. Apply grease to the O-rings (F) and install them onto the 12 mm flange bolts with a torque of 25 Nm (2.5 kgf·m).
85. Fit the bracket to the steering rack using the 12mm flange bolts.
86. Fix the steering gear housing in a clamp, then place the special tool on the lock screw (A). Tighten the lock screw to the specified torque. Remove the special tool.
87. Tighten the 12mm flange bolts (A) to the specified torque.
88. After tightening the 12mm flange bolts, place a lock washer (B) on the head of one of the bolts (C), making sure that the tabs (D) of the lock washer are on the flat surfaces (E) of the bolt head.
89. Remove any grease or dirt from the boot grooves around the body.
90. Release the boot (A) by removing the vinyl tape and insert the ends of the boot (B) into the grooves on the cylinder body.
91. Crimp the U-shaped part (A) of the clamp bands (B) with Oetiker 1098 pliers (available for sale) or equivalent (C).
92. Screw the plug (A) into the end of the rack.
93. Remove any grease or dirt from the grooves (C) under the boots around the body.
94. Move the steering rack and adjust the distance between the end of the cylinder body and the end of the rack plug to 70.5 mm. Install boot B and insert the ends of the boot properly into the grooves in the cylinder body and in the end plug of the rack. Install the clamp (D) and boot protector (E). Place the new boot clamp (F) into the boot grooves B, aligning the tongues (G) with the holes (H) in the clamp.
95. Crimp the U-shaped part (A) of the clamp band (B) with Oetiker 1098 pliers (available for sale) or equivalent (C). Move the rack to the right and left and make sure that the covers are not deformed or twisted.
96. Place a new lock washer (A) on the steering rod (B) with the radius side facing the steering rod, and screw the steering rod into the bracket (C), repeat the operation on the other steering rod. Hold the bracket with one wrench and tighten both tie rods to the required torque with the other wrench.
97. Bend the lock washer onto the flat areas of the bracket using large pliers.
98. Connect the cylinder tubes (A) and the outlet tube fitting (B).
Perform the assembly taking into account the following:
- Clean the cylinder tube fittings thoroughly. They should not contain any foreign substances.
- Connect the cylinder tubes by first tightening the flare nuts by hand, then to the required torque.
99. Adjust the guide rail screw. After adjustment, make sure the rack moves smoothly by moving it right and left.