Basic Inspection

Clean all disassembled parts, and check for wear, damage or any other faults, then repair or replace as necessary.
When disassembling, check the inside of gearbox for water. If any water is found, carefully check the boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts.

PROBLEM SYMPTOM CHART

No.	Parts	Inspection	Corrective action
1	Input shaft	Bend of input shaft Damage on serration	If the bend or damage is excessive, replace the entire gearbox.
2	Dust seal	Crack or damage Wear	If the outer wall slips, the lip is worn out or damage is found, replace it with a new one.
3	Rack & pinion	Poor mating of rack with pinion	Adjust the backlash properly. By measuring the turning torque of gearbox and sliding resistance of rack, check if rack & pinion engage uniformly and smoothly with each other. (Refer to "Service limit".) Keeping the rack pulled out all the way so that all teeth emerge, check teeth for damage. Even if abnormality is found in either (1) or (2), replace the entire gearbox.
4	Gearbox unit	Bend of rack shaft Bend of cylinder portion Crack or damage on cast iron portion	Replace the gearbox with a new one.
		(4) Wear or damage on rack bush	If the free play of rack shaft in radial direction is out of the specified range, replace the gearbox with a new one. (Refer to"Service limit".)
		(5) Wear on input shaft bearing	If the free plays of input shaft in radial and axial directions are out of the specified ranges, replace the gearbox with a new one. (Refer to "Service limit".)
5	Boot	Crack, damage or deterioration	Replace
6	Tie-rod	Looseness of ball joint Bend of tie-rod	Replace.
7	Tie-rod end	Damage or deterioration on dust seal	Replace
8	Adjusting screw spring	Deterioration	Replace
9	Boot clip	Deterioration	Replace
10	Sleeve	Damage	Replace
11	Pipes	Damage to flared surface Damage to flare nut Damage to pipe	Replace.