Disassembly
1. Disconnect the oil supply and return lines from the hydraulic booster. Plug the ends of the lines to protect them from contamination.
2. Disconnect the ball joint ends from the steering rods after loosening the lock nuts.
3. Remove the casing mounting clamps and protective rubber casings from the transmission housing.
4. Move the rack from stop to stop to remove any oil remaining in the hydraulic booster.
5. Move the rack to the extreme position and clamp the rack (by the teeth) in a vice.
6. Remove the steering rod mounting clamps and disconnect the steering rods from the toothed rack.
7. Unscrew the pusher cover bolts, remove the cover, remove the adjusting linings, spring and pusher.
8. Unscrew the lower plug from the steering gear drive pinion housing.
9. Unscrew the steering gear drive pinion lock nut.
10. Mark the position of the drive pinion corresponding to forward movement, as well as the protrusion of the toothed rack on both sides of the housing.
11. Remove the steering gear pinion housing and bearing retaining ring.
12. Remove the steering gear drive pinion from the housing together with the bearing.
13. Remove the flat gasket, seal and bearing from the drive pinion shaft.
14. Mark the position of the rack housing and threaded mounting ring relative to the drive pinion housing.
15. Unscrew the threaded mounting ring, remove the rack casing, take out the O-ring and nylon spacer.
16. Clamp the drive gear housing in a vice.
17. Remove the toothed rack and spacer sleeve.
18. Remove the retaining ring from the spacer sleeve without damaging the toothed rack and remove the gasket, circular gasket and booster piston gasket. Remove the other flat gasket and retaining ring.
19. Remove the spacer sleeve.
20. Remove the rack seal and beveled spacer from the spacer sleeve.
Checking the toothed rack
1. Check the condition of the interacting surfaces:
- sealing ring with steering gear drive shaft;
- teeth of the rack and pinion, as well as the working surface of the pusher;
- teflon seal of the steering gear separator valve.
2. Check and flush hydraulic lines and channels:
- pipelines and by-pass channel in the rack housing;
- dividing valve.
3. Replace worn or damaged parts and lubricate the edges of the sealing rings with Calipsol grease.
Caution! The Teflon ring of the separating valve nipple should be dipped in boiling water immediately before installation so that it can be positioned correctly.
Caution: The steering gear pinion and the separator valve are supplied in pairs and must be replaced together.
Assembly
1. Install a new sealing ring into the drive gear housing.
2. Place the rack in a vice.
3. Insert the spacer sleeve with the beveled gasket and sealing ring onto the toothed rack.
4. Install the piston gasket with a new O-ring.
5. Install flat gaskets and snap rings.
Caution! When installing the retaining rings, be careful not to damage the toothed rack.
6. Install the nylon bushing and O-ring into the drive gear housing.
7. Insert 40 g of solid lubricant between the teeth of the rack and move it in the housing until the spacer sleeve stops in the gear housing.
8. Lubricate the threaded housing mounting ring with oil. Install the housing and drive gear housing in accordance with the markings made during the transmission disassembly process.
9. Tighten the threaded ring using the appropriate key and secure it from unscrewing by punching the drive gear housing at the places where the ring is cut.
10. Insert the lower drive pinion bearing and snap ring.
11. Set the toothed rack to the middle position and insert the drive pinion in accordance with the markings made during the process of disassembling the transmission.
12. Place the top gasket and retaining ring onto the drive pinion shaft.
13. Tighten the drive gear lock nut and install the housing filled with solid lubricant.
14. Install the pusher, spring, clearance adjusting shim, and cover coated with sealing paste.
15. Move the rack so that its teeth are visible. Clamp it in a vice, secure the steering rods and insert new clamps.
16. Install the rubber protective covers and secure them with new mounting clamps.
17. Screw the ends with ball joints to the steering rods and secure them from unscrewing with lock nuts.