Disassembly
1. Clamp the steering gear (1) in a vice (2) with protective aluminum pads.
Note: When fixing, the jaws of the vice must be positioned on the fastening part of the steering gear housing.
2. Disconnect the tip (3) from the steering rod (4).
3. Remove the large steering gear boot clamp (5).
4. Remove the small steering gear boot clamp (6).
5. Pull the boot outward towards the steering rod.
6. Remove the power steering tubes (7) from the steering gear.
7. Slowly moving the toothed rack, drain the working fluid from the crankcase.
8. Remove the steering rod (8) from the toothed rack (9).
Caution: Do not turn the rack when removing the rod.
9. Unscrew the lock nut (10) of the rack stop plug.
10. Using a wrench, unscrew the plug (11).
11. Remove the lock nut (12), plug (13), spring (14) and rack stop (15).
12. Turn the rack stopper to remove the end of the stop ring from the groove in the crankcase. Once the end of the stop ring has exited the hole (16) in the crankcase (17), turn the stopper (18) clockwise and remove the stop ring.
13. Remove the rack bushing and the rack itself from the steering gear housing.
14. Remove the sealing ring (19) from the rack (20).
15. Remove the oil seal (21) from the rack bushing (22).
16. Unscrew the plug and unscrew the gear nut.
17. Using a rubber hammer, knock out the gear with the spool valve and seal from the steering gear housing.
18. Using a suitable tool, remove the seal and bearing from the distributor housing.
19. Remove the oil seal and O-ring from the crankcase.
Caution: Be careful not to damage the inner surface of the crankcase.
20. Using a suitable tool, remove the oil seal (23) from the crankcase.
Examination
21. Check the toothed rack for wear, damage or deformation.
22. Check the condition of the seals.
23. Check the rack and pinion teeth for wear and damage.
24. Check for ease of rotation, absence of beating and noise in the bearings.
Assembly
Note: Apply power steering fluid to all seals and O-rings before installing them.
25. Install the washer and seal (24) into the steering gear housing.
26. Install the oil seal (25) into the rack bushing (26).
27. Apply grease to the rack teeth.
Note: Make sure that no grease gets into the outlet hole (27) of the rack.
28. Insert the rack (28) into the steering gear housing (29) and install the bushing (30).
29. Using a suitable tool, install the 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 screw in the plug. Apply sealant to the threads of the plug before installing it.
32. Set the rack to the middle position.
33. Tighten the rack stop plug. Tightening torque: 9-11 Nm (without booster); 20 Nm (with booster).
34. Slowly move the rack from side to side 5 times.
35. Set the rack back to the middle position and loosen the plug.
36. Tighten the plug to the specified torque, then back it off in the opposite direction by the specified amount. Tightening torque: 4.5-6.5 Nm (without booster); 5-6 Nm (with booster).
Turning range: 25° ±5° (without amplifier); 35° (with amplifier).
37. Tighten the rack stop lock nut. Tightening torque: 40-50 Nm (without booster); 50-60 Nm (with booster).
38. Install the booster pipes and tighten the nuts. Tightening torque: 25-30 Nm.
39. Install the steering rod.
40. Apply grease to the steering rod groove.
41. Install the steering rod boot and secure it with new clamps. Make sure the boots are not twisted.
42. Install the tie rod end.
43. Check the tension of the steering gear pinion.