Power Steering Gear: Disassembly

Using SST, secure the PS gear assembly in a vise. SST 09612-00012.

Fig 1: Securing PS Gear In Vise

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1. Using SST, remove the 2 turn pressure tubes. SST 09023-38200.
   Fig 2: Identifying Pressure Tube Union Nuts

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2. Remove the 4 O-rings from the 2 turn pressure tubes.

1. Place matchmarks on the tie rod end and rack end.
   Fig 3: Matchmarking Tie Rod & Rack End

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2. Loosen the lock nut, and remove the tie rod end and lock nut.
3. Employ the same manner described above to the other side.

CAUTION: Be careful not to damage the boot.
Fig 4: Removing Clamps
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1. Using pliers, loosen the clamp.
NOTE: Mark the RH and LH rack boots.
2. Remove the clip and boot.
3. Employ the same manner described above to the other side.

CAUTION: Avoid any impact on the steering rack.
Fig 5: Unstaking Washer
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1. Using a chisel and hammer, unstake the washer.
NOTE:
• Use SST 09922-10010 in the direction shown in the illustration.
• Mark the RH and LH rack ends.
Fig 6: Remove Rack End & Claw Washer
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2. Using SST, remove the rack end and claw washer. SST 09922-10010.
3. Employ the same manner described above to the other side.

1. Using a hexagon wrench (19 mm), remove the rack guide spring cap.
2. Remove the rack guide spring, conical spring washer, rack guide subassembly.

1. Place matchmarks on the control valve housing and rack housing.
   Fig 9: Matchmarking Control Valve & Rack Housing

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2. Remove the 2 bolts and control valve housing with the control valve assembly.
3. Remove the gasket from the control valve housing.

1. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
CAUTION: Be careful not to damage the oil seal lip.
Fig 10: Removing Control Valve Assembly
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2. Using a plastic hammer, tap out the control valve assembly with the oil seal from the control valve housing.
3. Remove the oil seal from the control valve assembly.
   Fig 11: Removing Oil Seal From Control Valve

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1. Using SST, turn the cylinder end stopper clockwise until the wire end is visible through the service hole. SST 09631-10021
2. Using SST, turn the cylinder end stopper counterclockwise, and remove the wire. SST 09631-10021.

CAUTION: Take care not to drop the steering rack.
Fig 12: Remove Steering Rack Bushing
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1. Using SST, press out the steering rack with the bushing. SST 09612-24014 (09612-10061).
2. Remove the O-ring from the bushing.