Disassembly
1. Disconnect the oil supply and return lines from the hydraulic booster. Plug the ends of the pipelines with plugs to protect against contamination.
2. Disconnect the ball joints from the tie rods after loosening the locknuts.
3. Remove the casing fastening clamps and protective rubber casings from the transmission housing.
4. Move the rack from stop to stop to remove oil remaining in the hydraulic booster.
5. Move the rack to the end position and clamp the rack (for the teeth) in a vice.
6. Remove the tie rod retainers and disconnect the tie rods from the rack.
7. Unscrew the pusher cover bolts, remove the cover, remove the shims, spring and pusher.
8. Remove the bottom plug from the steering gear housing.
9. Loosen the steering gear lock nut.
10. Mark the position of the drive gear corresponding to the forward movement, as well as the protrusion of the rack on both sides of the housing.
11. Remove the steering gear cover and bearing circlip.
12. Remove the steering gear from the housing together with the bearing.
13. Remove the flat gasket, seal and bearing from the drive gear shaft.
14. Mark the position of the rack housing and the threaded adjusting ring in relation to the drive pinion housing.
15. Unscrew the threaded ring, remove the rack cover, remove the O-ring and the nylon spacer.
16. Clamp the drive gear housing in a vise.
17. Remove toothed rack and spacer.
18. Remove, without damaging the rack, the retaining ring from the spacer sleeve and remove the gasket, O-ring and booster piston gasket. Remove the other flat gasket and circlip.
19. Remove spacer.
20. Remove the rack seal and beveled spacer from the spacer bush.
Checking the rack
1. Check the condition of interacting surfaces:
- O-ring with steering gear drive shaft;
- teeth of the rack and pinion, as well as the working surface of the pusher;
- Teflon seal for the steering gear split valve.
2. Check and flush hydraulic lines and channels:
- pipelines and bypass channel (by-pass) in the gear rack housing;
- separating valve.
3. Replace worn or damaged parts and lubricate O-ring lips with Calipsol grease.
Attention! The Teflon ring of the separation valve fitting must be immersed in boiling water immediately before installation so that it can be properly positioned.
Attention! The steering gear and splitter valve come in pairs and must be replaced together.
Assembly
1. Install a new O-ring in the drive gear housing.
2. Install the gear rack in a vise.
3. Insert the spacer sleeve with beveled gasket and O-ring onto the rack.
4. Install the piston gasket with a new O-ring.
5. Put on flat gaskets and circlips.
Attention! In the process of installing the retaining rings, the gear rack must be protected from damage.
6. Install the nylon bushing and O-ring in the pinion housing.
7. Introduce 40 g of solid lubricant between the teeth of the gear rack and move it in the housing until the distance sleeve stops against the gear housing.
8. Lubricate the threaded housing set ring with oil. Install the casing and drive gear housing in accordance with the designations made during the disassembly of the transmission.
9. Tighten the threaded ring with a suitable wrench and secure it against unscrewing by punching the drive gear housing in the places where the ring is cut.
10. Insert lower drive gear bearing and circlip.
11. Set the toothed rack in the middle position and insert the drive gear in accordance with the designations made during the disassembly of the transmission.
12. Slide the top gasket and circlip onto the drive gear shaft.
13. Tighten the drive gear locknut and install the guard filled with solid lubricant.
14. Install the tappet, spring, gap adjusting shim, and cover lubricated with sealing paste.
15. Move the rack so that its teeth are visible. Clamp it in a vise, secure the tie rods and insert new clips.
16. Install the rubber protective covers and fix them with new fastening clamps.
17. Screw the ends with ball joints to the steering rods and secure them against unscrewing with locknuts.
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