Attention.
- If you clamp the steering mechanism in a vice to perform work, place wooden blocks. If the hollow center part of the steering gear is squeezed too hard, it may become deformed.
- Store the removed components away from dust.
1. Cut the boot strap at the location shown in the illustration and remove it.
2. Remove the rail tip clip and remove the cover (on the left and right sides).
3. Bend the tabs of the lock washer.
4. Remove the tips from the rail.
To loosen the tip, hold the rail with a wrench on the edges at the end of the rail (only on the right side).
Attention. When unscrewing the tip with the keys, do not scratch the rubbing surfaces of the rail.
5. Loosen the lock nut and unscrew the rail guide screw.
6. Disconnect tubes A and B of the cylinder.
Attention. While loosening the cap nuts on the cylinder side, hold the cylinder nipple with a wrench.
7. Remove the fluid from the steering mechanism through the tube fittings by slowly moving the rack..
8. Clamp the steering mechanism in a vise and use the special tool to loosen the upper valve plug.
9. Unscrew the top plug of the valve.
10. Remove the gear/clutch shaft.
11. Check the coupling O-ring for detachment and replace the O-ring if necessary.
12. Check the outside of the clutch for damage and replace the gear/clutch shaft if necessary.
The coupling is not removed from the shaft. If any component is damaged, replace the gear/clutch shaft assembly.
13. Cut the o-rings of the coupling with a knife and remove them.
Attention. Do not damage the outer surface of the coupling and groove.
14. If you can feel the stepped wear inside the housing with your finger, replace the steering gear housing.
15. Using a special tool, remove the oil seal.
16. Using a drill, drill a hole with a diameter of 3 mm and a depth of 2.5-3.0 mm at the punching site.
Make sure that chips do not get into the steering mechanism.
After removing the tip, remove any burrs left by drilling as they may damage the gland and boot during installation.
17. Fix the steering gear housing on the workbench, loosen and unscrew the tip of the cylinder.
18. Using a suitable bearing puller, install the steering gear on the press.
19. Fully lower the steering rack and insert the extension (length 350 mm) with a socket wrench, the outer diameter of which is approximately equal to the diameter of the rack, into the steering gear.
Attention. Because a large force will be applied to the rail, before pressing out, make sure of the following:
- Is the extension cord tilted?
- Are the centers of the press adapter and extension cord misaligned;
- Whether the steering gear is securely fastened with a puller.
20. Press the rail through the extension and push it down.
When the cylinder end seal comes out, the rack will fall down, so hold it.
21. Remove the steering mechanism from the press and remove the rail with the mechanical bearing.
22. Insert a flat washer with a diameter of 28 mm (№ 94103-10400) into the steering gear and place on the backup ring.
23. Insert the special tool into the steering mechanism and install on the press, in the same way as in paragraph 18.
24. Press down on the flat washer (through a special tool) and press out the backup ring together with the end seal of the cylinder.
Attention:
- If the special tool is tilted, the inner wall of the cylinder may be scratched, so correct the position of the special tool if necessary.
- Be sure to use a press to remove. If you hit the special tool, the back-up ring may burst and it will become impossible to remove the end seal.
25. Cut the O-ring and piston O-ring with a knife and remove them.
Attention. Be careful not to damage the piston surface and ring grooves.