Disassemble

Tool Required
^ 999 5046 Fixture
^ 999 2250 Stand
^ 999 5154 Stand
^ 999 5179 Socket
^ 999 5333 Pin Spanner
^ 999 5389 Dressing Tool





1. Clean outside of steering gear. Disconnect pressure lines and remove O-rings.

NOTE: Pressure lines on later cars are provided with tapered seals.





2. Mount steering gear in fixture and stand. Use U-bolt 1272597-4 and intermediate piece 1272679-0 to mount assembly.





3. Drain fluid from steering gear:
a. Place container under fluid line connections to collect fluid. Turn pinion shaft back and forth with socket 999 5179 and handle to pump out fluid.
b. Adjust rack approximately to mid-position.





4. Inspect inner and outer ball joints for signs of wear.
5. Remove:
a. Outer ball joints .
b. Clamps and boots (gaiters).
c. Boot sealing rings on housing.





6. Remove left-hand tie rod (track rod) and slacken right-hand rod a few turns.
a. Use adjustable wrench and adjustable pliers. Position wrench as far along rack as possible to act as counterhold.
b. Remove/slacken tie rods (track rods).

NOTE: Rods are provided with spacers on certain versions. Use counterhold, otherwise rack and pinion may be damaged. Right or left rod (as appropriate) should remain in position to prevent escape of end bushing.





7. Remove:
a. Sealant covering locking wire hole.
b. Rack bushing locking wire.
c. Turn end sleeve with hook spanner until locking wire emerges and can be removed.

NOTE: It may be necessary to use a pointed chisel to pry out the end of the wire.





8. Clean rack bushing and seal by blowing with compressed air. Hold pinion shaft with socket and handle. Blow through outer pipe connection until bushing and seal emerge. Tie rod (track rod) will act as stop to prevent escape of bushing.

NOTE: Use hearing protectors since compressed air may produce loud noise.





9. Remove:
a. Tie rod (track rod).
b. Bushing and seal.





10. Remove preload assembly Use pin spanner to remove cover. Remove cover, spring and preload piston.





11. Remove piston dust seal and snap ring (Circlip). Use screwdriver to remove dust seal, taking care to avoid damage to pinion or steering gear housing.





12. Remove pinion cover. Insert chisel and tap off cover.





13. Remove pinion locknut. Use socket and handle to counterhold pinion shaft when removing locknut.





14. Remove pinion assembly. Use brass drift and hammer to tap out assembly from lower end.





15. Remove rack. Withdraw rack carefully to avoid damage to internal surfaces of rack and housing.





16. Tap out pinion ball bearing from above. Remove snap ring (circlip) and tap out bearing with drift.





17. Tap out pinion lower seal and bushing from underneath. Use long extension bar and 24 mm (9.45 inch) o.d. socket.





18. Tap out rack seal and backing ring from steering gear housing:
a. Use two extension bars and 25 mm (9.84 inch) o.d. socket.
b. Insert extension bars and socket through steering gear housing, ensuring that socket grips edge of backing ring. Tap out seal and backing ring.

NOTE: Take care to avoid damage to internal surfaces of housing.





19. Piston seal. Replace piston seal only if damaged or if car has covered more than 40,000 km (25,000 miles).





20. Remove from pinion:
a. Socket (1).
b. Dust seal (2).
c. Snap ring (circlip) (3).
d. Seal (4).
e. Roller bearing (5).

NOTE: The four teflon seals on the rotary valve sleeve must not be removed.





21. Clean and inspect all components. Inspect:
- Boots (gaiters); replace as required.
- Boot seals; replace as required.
- All components for wear, corrosion, cracks and pressure damage.
- Pinion and valve sleeve. Complete steering gear must be replaced if these components are damaged.

NOTE: Carefully clean and dress threads in steering gear housing. Use dressing tool for preload device cover.