2. Place the o-ring and O-ring on the tapered section of the special tool and slide them to the end of the special tool.
- In order for the sealing ring to stretch evenly, press evenly around the entire circumference.
- Do not stretch the o-ring more than required.
3. Align the end of the special tool with the groove and push the O-ring into the groove.
4. Push the o-ring in and place it on the o-ring.
After installation, press the O-ring evenly by hand.
5. Apply steering fluid to the inside of the special tool.
6. Staggering the special tool in different directions, evenly crimp the sealing ring with the conical section of the special tool.
Do not damage the O-ring with the special tool.
7. Wrap two or three layers of vinyl tape around the toothed rack and apply steering fluid on top.
8. Apply steering fluid to the inner surface of the end seal and install the seal together with the backup ring on the rack.
Point the grooved side of the seal toward the piston.
Do not damage the oil seal with the rack teeth.
To prevent components from falling off, apply grease to the backup ring on the gland side and press against the gland.
9. Remove the vinyl tape from the rail.
10. Before installing the rack into the steering gear case, mark the size A on the extension.
Use an extension approx. 350 mm and a socket wrench, the outer diameter of which is approximately equal to the diameter of the rail.
11. Remove the burr inside the cylinder from the reaming.
If the burrs are not completely removed, the seal may be damaged.
Be careful not to get metal filings into the cylinder.
12. Cover the threads in the cylinder with vinyl tape and apply steering fluid.
13. Apply grease to the teeth and insert the rack into the steering gear housing.
Attention. Do not scratch the inside surface of the cylinder with the end of the rack.
14. Install the steering gear housing with rack inserted on the press with the side of the cylinder up.
15. Install the labeled extension on the end of the rail.
16. Press the rail so that the mark coincides with the end face of the cylinder.
Attention. Do not press further than the mark, as the seal may be damaged.
17. Remove the steering gear from the press.
18. Slowly return the steering rack to the center position, wrap the left end of the rack (cylinder side) vinyl tape and apply steering fluid to it.
Do not extend the rack more than necessary, as the already pressed oil seal can be damaged by the teeth of the rack.
19. Apply steering fluid to the end seal of the cylinder and install it on the rail.
Guide the seal with the groove towards the piston.
20. Remove the vinyl tape.
Attention. Do not leave the vinyl tape on the rail, remove completely.
21. Lightly press the oil seal into the cylinder by hand and use the special tool to press the oil seal to a depth of approx. 60 mm.
Put a mark on the special tool at a distance of 60 mm from its end.
The seal must come completely off the vinyl tape covering the threaded section of the cylinder.
22. Remove the vinyl tape from the threaded section of the cylinder.
Attention. Completely remove the vinyl tape.
23. Install the steering gear housing on the workbench and secure it to the flange.
24. Screw on the tip of the cylinder and tighten to the required torque.
25. Fix the tip by punching from the side opposite to the place of the previous punching.
26. Pack grease into the stuffing box and, using the special tool, drive it into the steering gear housing, pointing the side with the groove towards the valve.
27. Apply steering fluid to the special tool and install the o-ring on it, stretching the tapered section.
Do not leave the rings stretched for a long time, but immediately "install on the clutch.
28. Align the end of the special tool with the groove on the coupling and install the O-ring into the groove.
Install the rest of the rings in the same way.
After installation, press the O-ring evenly by hand.
29. Wrap the sealing ring with a rubber tube and crimp it with a clamp.
30. Pack grease into the needle bearing located in the steering gear housing.
31. Apply steering fluid to the clutch o-rings and insert the gear/clutch shaft into the steering gear housing.
32. Fix the steering gear in a vise.
33. Pack grease into the stuffing box in the upper valve plug and apply steering fluid to the O-ring.
34. Press the upper valve plug into the steering gear housing by hand.
35. Using the special tool, tighten the plug to the required torque.
36. Lock the top plug at the border with the body.
37. Install tubes A and B and tighten the union nuts to the required torque.
Thoroughly clean the connection areas from contamination.
38. Apply grease to the friction surfaces of the guide rack and install it in the steering gear housing.
39. Completely remove the old sealant from the guide screw and apply new sealant to the threaded area.
40. Install the spring and tighten the screw.
41. Tighten the jam nut by hand and adjust the guide rail (see above).
42. Install the rubber retaining ring on the end of the rail.
43. Align the tabs of the lock washer with the slots on the end of the rail and install it on the rail.
44. Screw the rack tip into the steering rack while holding the lock washer with your hand.
45. Tighten the tip of the rail with the required force, holding the end of the rail with a wrench.
Attention. Do not damage the rubbing surfaces of the rack while tightening.
46. Bend the lock washer towards the tip of the rack.
47. Apply lubricant to the surface of the tip that rubs against the boot.
48. Install the cover.
- If grease gets on the threads, remove it.
- If the cover is reused, check for damage or deformation and replace if necessary.
49. Install boot clamp as shown.
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50. Crimp the collar of the cover.
Crimp the crimp area of the clamp with tongs so that a gap of 1.8-2.3 mm remains.
51. Move the rail left and right and make sure that the covers are not twisted or squeezed.