Disassembly
1. Clamp the steering gear (1) in a vice (2) with protective aluminum lining.
Attention: when fixing, the vise jaws must be located on the mounting part of the steering gear housing.
2. Detach the handpiece (3) from the tie rod (4).
3. Remove the large steering boot clamp (5).
4. Remove the small collar of the anther of the steering mechanism (6).
5. Pull the boot out towards the tie rod.
6. Remove amplifier tubes (7) from the steering gear.
7. Slowly moving the gear rack, drain the working fluid from the crankcase.
8. Remove the tie rod (8) from the rack (9).
Attention: do not turn the gear rack when removing the linkage.
9. Loosen the locknut (10) rail end caps.
10. Using the wrench, unscrew the plug (11).
11. Remove locknut (12), stub (13), spring (14) and rail stop (15).
12. Rotate the rack stopper to push the end of the retaining ring out of the crankcase slot. As soon as the end of the retaining ring comes out of the hole (16) crankcase (17), turn the stopper (18) clockwise and remove the retaining ring.
13. Remove the rack sleeve and the rack itself from the steering gear housing.
14. Remove the O-ring (19) from rail (20).
15. Remove the oil seal (21) from rail bushing (22).
16. Unscrew the plug and unscrew the gear nut.
17. Using a rubber mallet, knock out the gear with the spool valve and the oil seal from the steering gear housing.
18. Using a suitable tool, remove the oil seal and bearing from the distributor housing.
19. Remove the stuffing box and o-ring from the crankcase.
Caution: Be careful not to damage the inside of the crankcase.
20. Using a suitable tool, remove the oil seal (23) from the crankcase.
Examination
21. Check the gear rack for wear, damage or deformation.
22. Check up a condition of epiploons.
23. Check rack and pinion teeth for wear and damage.
24. Check the ease of rotation, the absence of runout and noise in the bearings.
Assembly
Note: Apply steering fluid to all oil seals and o-rings before installing them.
25. Install washer and seal (24) into the steering box.
26. Install the oil seal (25) into the rail bushing (26).
27. Apply grease to the rack teeth.
Note: Be careful not to get grease into the outlet (27) slats.
28. Insert rail (28) in the steering box (29) and install bushing (30).
29. Using a suitable tool, install the oil seal and bearing into the distributor housing.
30. Apply working fluid to the surface of the gear (31) and install it in the crankcase.
31. Install the rack stop, spring and tighten the plug. Before installing the plug, apply sealant to its threads.
32. Set the rail to the middle position.
33. Tighten the rack stop plug. Tightening torque: 9-11 Nm (without amplifier); 20 Nm (with amplifier).
34. Slowly move the staff from side to side 5 times.
35. Set the rail back to the middle position and loosen the plug.
36. Tighten the plug to the specified torque, and then unscrew it in the opposite direction by the specified amount. Tightening torque: 4.5-6.5 Nm (without amplifier); 5-6 Nm (with amplifier).
Loosening amount: 25°± 5° (without amplifier); 35° (with amplifier).
37. Tighten the rack stop jam nut. Tightening torque: 40-50 Nm (without amplifier); 50-60 Nm (with amplifier).
38. Install the amplifier pipes and tighten the nuts. Tightening torque: 25-30 Nm.
39. Install the tie rod.
40. Apply grease to the tie rod groove.
41. Establish a boot of steering draft and fix it with new collars. Make sure the anthers are not twisted.
42. Install the tie rod end.
43. Check the tightness of the steering gear.