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Steering Rack End Removal and Installation


RHD model

LHD model
Removal
NOTE:
  • Do not allow dust, dirt, or other foreign materials to enter the steering gearbox.
  • The illustrations show RHD model, LHD model is similar for items not shown in this section.
  1. Remove the boot bands (A) and discard them. Remove the tie-rod clips (B), and pull the boots away from the ends of the steering gearbox.

  1. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) as shown. Do not clamp the cylinder part of the gearbox housing in the vise.

  1. Unbend the lock washer (A).

  1. Hold the flat surface sections (A) of the steering rack (B) with one wrench, and unscrew both rack ends (C) with another wrench. Be careful not to damage the rack shaft surface with the wrench.
  1. Remove the lock washer (D) and rubber stop (E).

Installation
  1. Hold the gearbox housing using a C-clamp (A) and wooden blocks (B) as shown. Do not clamp the cylinder part of the gearbox housing in the vise.

  1. Install the new rubber stop (A) and a new lock washer (B). Align the lock washer tabs (C) with the slots (D) on the rack end (E) while holding the lock washer in place. Repeat this step for the other side of the rack.
  1. Hold the flat surface sections of the steering rack with one wrench, and tighten both rack ends with another wrench. Be careful not to damage the rack surface with the wrench.

  1. Bend the lock washer (A) back against the flat spots on the rack end joint housing.

  1. Apply multipurpose grease to the circumference of the rack end joint housing (A).
  1. Apply a light coat of silicone grease to the boot grooves (B) on the rack end.

  1. Clean off any grease or contamination from the boot installation grooves (A) around on the gearbox housing. Install the boots (B) on the rack ends with the tie-rod clips (C), and fit the boot end in the installation grooves in the housing properly.
  1. After installing the boots, wipe the grease off the thread section (D) of the rack end.

  1. Install the new boot bands by aligning the tabs (A) with the holes (B) of the band.

  1. Close the ear portion (A) of the boot band (B) with commercially available pincers, Oetiker 1098 or equivalent (C).
  1. Slide the rack right and left to be certain that the boots are not deformed or twisted.
  1. Install the tie-rod end to the rack end.