Pic. 5.22. Steering gear
Drain the hydraulic fluid from the booster hydraulic system.
Disconnect the pressure and return pipes from the steering gear fittings.
Pic. 5.23. Disconnecting the cardan shaft
Disconnect the steering cardan shaft from the steering gear inside the passenger compartment (pic. 5.23).
Pic. 5.24. Disconnecting the tie rod end
With a special tool (09568-31000), disconnect the tie rod end from the steering knuckle (pic. 5.24).
Pic. 5.25. Steering tubes
Remove steering tubes (pic. 5.25).
Remove the steering gear mounting bolts and remove the steering gear assembly with rubber mounts.
Attention! When removing the steering gear assembly, remove the steering gear slowly and very carefully so as not to damage the tie rod boot and the tie rod end ball joint boot.
Disassembly
Pic. 5.26. Removing the tie rod end
Remove the tie rod end from the tie rod (pic. 5.26).
Pic. 5.27. Removing the boot from the ball joint
Remove boot from ball joint (pic. 5.27).
Pic. 5.28. Removal of a large collar of fastening of a protective cover of steering draft
Remove the large clamp securing the protective cover of the tie rod (pic. 5.28).
Pic. 5.29. Removal of a small collar of fastening of a protective cover of steering draft
Remove the small collar of the protective cover of the tie rod (pic. 5.29).
Pull off a protective cover from the case of the steering mechanism on steering draft.
Note. When replacing the protective boot, check that there is no rust on the steering rack.
Disconnect the steering tubes from the valve body and steering gear and remove them.
Slowly moving the rack, drain the working fluid from the steering gear housing.
Pic. 5.30. Chasing the lock washer fixing the steering rod and steering rack
Using a chisel, chisel out the lock washer that secures the tie rod and steering rack (pic. 5.30).
Pic. 5.31. Removing the tie rod
Remove the tie rod from the steering rack (pic. 5.31).
Attention! Be careful when removing the tie rod from the steering rack, do not bend the rack.
Pic. 5.32. Unscrewing the locknut of the rack stop cover
Loosen the lock nut of the rack stop cover (pic. 5.32).
Pic. 5.33. Removing the rack stop cover
Using a special tool (09565-31300), remove the rack stop cover (pic. 5.33).
Pic. 5.34. Steering housing components
Remove the rack stop spring, rack stop, rack stop cover and bushing from the steering box (pic. 5.34).
Pic. 5.35. Plug and self-locking nut
Remove the plug and self-locking nut (pic. 5.35).
Remove the circlip using a circlip plier.
Pic. 5.36. Removing the pinion and valve assembly
Remove pinion and valve assembly with upper seal using a plastic-faced hammer (pic. 5.36).
Pic. 5.37. Retaining Ring Rotation Before Removal
Turn the rack travel stop clockwise until the end of the retaining ring comes out of the slot in the steering gear housing (pic. 5.37).
Pic. 5.38. Removal of a lock ring from a groove of the case of the steering mechanism
Once the end of the retaining ring is out of the slot in the steering gear housing, turn the rack travel stop counterclockwise and remove the retaining ring (pic. 5.38).
Attention! Do not damage the rail during disassembly.
Pic. 5.39. Removing the rack travel stop
Remove the rack travel stop, rack support sleeve and steering rack from the steering gear housing at the plunger side (pic. 5.39).
Attention! After removing the rail, replace the oil seal on the body side with a new one.
Pic. 5.40. Removing the O-ring
Remove the o-ring from the rack support sleeve (pic. 5.40).
Pic. 5.41. Removing the oil seal from the rack support sleeve
Remove the oil seal from the rack support sleeve (pic. 5.41).
Checking the steering rack
Check for wear or damage on the steering rack teeth.
Check the contact surface for oil seal installation for excessive wear or damage.
Pic. 5.42. steering rack
Check the straightness of the steering rack (no bending or twisting) (pic. 5.42).
Check the O-ring for excessive wear or damage.
Check the oil seal for excessive wear or damage.
Pic. 5.43. pinion
Check drive gear teeth for wear or damage (pic. 5.43).
Check the contact surface for oil seal installation for excessive wear or damage.
Check the O-ring for excessive wear or damage.
Check the oil seal for excessive wear or damage.
Check the smoothness of rotation and the absence of extraneous noise during the operation of the bearings.
Check for excessive play in the bearings.
Check that the needles are not falling out of the needle bearing.
Check for damage to the inner surface of the steering gear housing cylinder.
Check protective covers for wear, cracks or tears.
Assembly
Apply the recommended working fluid to the working lip of the steering rack oil seal around its entire circumference.
Recommended working fluid: PSF-3.
Pic. 5.44. Installation of an epiploon in the case of the steering mechanism
With a special tool (09431-11000), establish an epiploon in the case of the steering mechanism, as it is shown in drawing 5.44.
Attention! Mark the direction of installation of the gland.
Attention! Use only a new seal.
Apply the recommended working fluid to the steering rack bearing bushing seal around its entire circumference.
Recommended working fluid: PSF-3
Install the oil seal on the rack support bushing.
Pic. 5.45. O-ring installation diagram
Apply the recommended hydraulic fluid to the O-ring and install it to the steering rack support bushing using the special tool (09431-11000) (pic. 5.45).
Apply the recommended grease to the steering rack teeth.
Pic. 5.46. Steering rack air vent
Attention! Do not fill the steering rack vent hole with grease (pic. 5.46).
Pic. 5.47. Installing the Rack Support Bushing and Rack Travel Stop
Insert the rack into the steering box, then install the rack support bushing and rack travel stop (pic. 5.47).
Insert the circlip into the rack travel stop hole through the hole in the steering box when the holes are aligned. Rotate the rack travel stop and finally secure the circlip.
Pic. 5.48. Retaining ring lock position
Attention! After installing the retaining ring, its ends must not be visible through the hole in the steering gear housing (pic. 5.48).
Pic. 5.49. Where to apply grease
Apply recommended hydraulic fluid and recommended grease to pinion gear and valve assembly and install in steering gear housing (pic. 5.49).
Recommended working fluid: PSF-3.
Recommended lubricant: SAE J310a, NLGI #2 General Purpose.
Pic. 5.50. Ball bearing installation diagram
Install the ball bearing with the special tool (09222-21100) (pic. 5.50).
Install the pinion and valve assembly into the valve body.
Pic. 5.51. Seal installation diagram
Install the oil seal with a special tool (09432-21601) (pic. 5.51).
Install the circlip using a circlip plier.
Pic. 5.52. Tightening the self-locking nut
Turn the drive gear fully clockwise and tighten the self-locking nut (pic. 5.52).
Attention! Always replace the self-locking nut with a new one.
Pic. 5.53. Plug tightening
Apply turning into «rubber» sealant (semydrying sealant) on the threaded part of the plug and tighten with the nominal torque (pic. 5.53).
Plug tightening torque: 50–70 Nm.
Lock the plug in two places with a punch.
Pic. 5.54. Caulking the ends of the lock washer
Install a new lock washer and tie rod. Caulk the edges of the lock washer in two places on the tie rod (pic. 5.54).
Note. Get in two places the antennae of the lock washer in the recesses of the steering rod.
Note. Always replace the lock washer with a new one before installation.
Pic. 5.55. The sequence of installation of components in the steering gear housing
Install the insert, rack stop, rack stop spring and rack stop cover in the steering gear housing in the sequence shown in Figure 5.55.
Apply turning into «rubber» sealant (semydrying sealant) on the threaded part of the rack stop cover before installing it.
Center the rack, then insert the rack stop cover into the steering box. Using the special tool, tighten the rail stop cover to 20–25 Nm. Turn the rack stop cover about 20 degrees and tighten the rack stop cover locknut to the specified torque.
Locknut tightening torque: 50–70 Nm.
After adjustment, install the rack stop cover with the lock nut.
Attention! If it is not possible to adjust the torque of the drive gear within the specified value of the angle of rotation, then check or replace the rack stop and rack stop cover parts.
Install and tighten the steering tubes to the specified torque, then install the rubber mounts in place with special adhesive (adhesive).
Apply the recommended grease to the tie rod end protector small collar (into the groove on the pull).
Recommended lubricant: SAE J310a, NLGI #2 General Purpose.
Install a new large tie rod boot clamp.
Note. Before installing the tie rod boot, always replace the large boot collar with a new one.
Pic. 5.56. Scheme of the correct installation of the protective cover
Install the tie rod boot in place without twisting it (pic. 5.56).
Pic. 5.57. Large clamp installation diagram
Fill the inner cavity of the protective boot of the ball joint of the tie rod end (A) and the working edge of the ball joint (B) recommended lubricant. Apply the recommended sealant to the sealing lip of the protective boot and fix it to the ball joint with a clamp (pic. 5.57).
Recommended lubricant: SAE J310a, NLGI #2 General Purpose.
Wrap the left and right tie rod ends so that the length of the protruding part of the rod on the left and right is the same and corresponds to the nominal value. Lock the position with the locknut.
Pic. 5.58. Length of the protruding part of the steering rod
Length of the protruding part of the steering rod: nominal value - 208.7 mm (pic. 5.58).
Install the steering assembly to the vehicle.