DISASSEMBLY AND REASSEMBLY

Disassembly steps >>K<< 1. Lock nut >>K<< 2. Tie rod end 3. Clip >>J<< 4. Bellows band 5. Bellows >>I<< 6. Tie rod >>I<< 7. Tab washer 8. Feed pipe 9. O-ring >>H<< · Total pinion torque adjustment >>G<< 10. Lock nut <<A>> >>G<< 11. Rack support cover 12. Support spring 13. Rack support 14. Valve housing assembly 15. O-ring <<B>> >>F<< 16. Circlip <<C>> 17. Rack stopper <<C>> >>E<< 18. Rack bushing <<C>> >>E<< 19. Oil seal <<C>> 20. O-ring <<C>> >>D<< 21. Rack assembly <<D>> >>C<< 22. Seal ring 23. O-ring <<E>> >>B<< 24. Oil seal 25. Gear housing <<F>> >>A<< 26. Gear housing mounting bushing

LUBRICATION AND SEALING POINTS

Use special tool MB991621 (rack support cover wrench) to remove the rack support cover.

1.Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing. 2.Turn the rack stopper anticlockwise to remove the circlip.

1.Pull out the rack slowly. Take out the rack stopper and the rack bushing at the same time.

2. caution Do not damage the oil seal press fitting surface. Partially bend the oil seal and remove it from the rack bushing.

Use a piece of pipe or similar tool to remove the oil seal from the gear housing.

Use the following special tools to remove the gear housing mount bushing. Installer cap (MD998812) Installer 100 (MD998813) Installer adopter (MD998822) Bearing installer (MD998368)

Use the following special tools to press-fit the gear housing mount bushing. Camshaft oil seal installer (MD999569) Lower arm bushing arbor (MB990996)

2.Using the following special tools, press the oil seal into the rack housing. MB991197: Bar (long type) MB991199: Oil Seal Installer

As the seal ring extends after installing, compress the seal ring with special tool MB991317 (seal ring installer) or your hand.

1. caution Do not close the vent hole in the rack with grease. Apply a coating of repair kit grease to the rack teeth face.

2.Cover the teeth side of rack assembly with special tool MB991213 (oil seal protector). 3.Apply ATF DEXRON III or DEXRON II to special tool, and to the outer surface of the seal ring and the O-ring. 4.Align the centre of the oil seal with the rack to prevent the retainer spring from slipping. Slowly insert the rack from power cylinder side.

1.Apply the specified fluid to the outside of the oil seal and use special tool MB990927 (installer adopter) to press-fit the oil seal into the bushing end.

2.Apply ATF DEXRON III or DEXRON II to the oil seal inner surface and the O-ring. 3.Wrap the rack end with plastic tape, and push the rack bushing onto the rack.

Insert the circlip to the rack stopper hole through cylinder hole. Turn the rack stopper clockwise and insert the circlip firmly.

3.Use special tool MB991621 (rack support cover wrench) to tighten the rack support cover to 23 ±2N·m. 4.Turn the rack support cover 30° anticlockwise. 5.Use the special tool to hold the rack support cover, and then tighten the lock nut to 59 ± 10 N·m.

1. caution Be sure there is no ratcheting or catching when operating the rack towards the shaft. Measure the total pinion torque through the whole stroke of the rack. Using special tool preload socket (MB991006), rotate the pinion shaft at the rate of one rotation in 4 to 6 seconds to check the total pinion torque and the change in torque. Standard value: Total pinion torque: 0.8 - 2.1 N·m [Change in torque: 0.6 N·m or less] 2. caution When adjusting, set at the highest value of the standard value range. note If the total pinion toque cannot be adjusted to the standard value within the specified return angle, check the rack support cover components and replace any parts if necessary. If the total pinion torque or the change in torque is outside the standard value, move the rack support cover 0 - 30°, and adjust the pinion torque again.

After installing the tie rod to the rack, fold tab washer end (two locations) to tie rod notch.

1.Turn the adjusting bolt of special tool boot band crimping tool (MB991561) to adjust the opening dimension (W) to the standard value. note The dimension (W) is adjusted by approximately 0.7 mm per one turn. note Do not turn the adjusting bolt more than one turn. Standard value (W): 2.9 mm <When more than 2.9 mm>: Screw in the adjusting bolt. <When less than 2.9 mm>: Loosen the adjusting bolt.

2. caution Hold the rack housing, and use special tool to crimp the bellows band securely. Crimp the bellows band until special tool touches the stopper. Use special tool boot band crimping tool (MB991561) to crimp the bellows band.

3.Check that crimped width (A) is within the standard value. Standard value (A): 2.4 - 2.8 mm <When more than 2.8 mm>: Readjust the dimension (W) of step (1) to the value calculated by the following equation, and repeat step (2). W = 5.5 mm - A [Example: if (A) is 2.9 mm, (W) is 2.6 mm.] <When less than 2.4 mm>: Remove the bellows band, readjust the dimension (W) of step (1) to the value calculated by the following equation, and use a new bellows band to repeat steps (2) to (3). W = 5.5 mm - A [Example: if (A) is 2.3 mm, (W) is 3.2 mm.]

Screw in the tie rod end to achieve the right and left length as illustrated. Lock with the lock nut. note The lock nuts must be tightened securely only after the steering gear is installed to the vehicle and toe-in is adjusted.