Steering Gearbox Overhaul (HATC Model)

Steering Gearbox Overhaul

Note these items during overhaul:

• Refer to the Exploded View as needed during this procedure.
  
• Do not allow dust, dirt, or other foreign materials to enter the gearbox.
  
• Do not try to disassemble the torque sensor. If the torque sensor is faulty, replace the steering gearbox as an assembly.
  

1.	Remove the steering gearbox.

2.	Remove the tie-rod end and locknut from the both rack ends.

3.	Remove the boot bands (A), and discard them.   ACB

4.	Remove the tie-rod clips (B), and pull the boots (C) away from the ends of the gearbox.

5.	Unbend the lock washer (A).   A

6.	Hold the flat surface sections (A) of the steering rack with a wrench, and unscrew the both rack ends with a wrench. Be careful not to damage the rack surface with the wrench. Remove the lock washers (B) and discard it.   BA

7.	Install the new lock washer (A) on the rack end. Align the lock washer tabs (B) with the slots (C) on the rack end while holding the lock washer in place. Repeat this step for the other side of the rack.   BACD 83 N·m (8.5 kgf·m, 61 lbf·ft)

8.	Hold the flat surface sections (D) of the steering rack with a wrench, and tighten both rack ends with a wrench. Be careful not to damage the rack surface with the wrench.

9.	Bend the lock washer (A) back against the flat spots on the rack end joint housing.   A

10.	Apply multipurpose grease (A) to the circumference of the rack end joint housing.   BA

11.	Apply a light coat of the silicone grease to the grooves (B) on the rack end.

12.	Clean off any grease or contamination from the groove around (A) on the mounting cushion and gearbox housing.   BCAD

13.	Center the steering rack within its stroke. Install the boots (B) in the rack ends with the tie-rod clips (C). Wipe the grease off the threaded section (D) of the rack end.

14.	Install the new boot bands by aligning the tabs (A) with the holes (B) on the band.   AB

15.	Close the ear portion (A) of the band with commercially available pincers Oetiker 1098 or equivalent (B).   A2 mm (0.08 in.)B

16.	Slide the rack right and left to be certain that the boots are not deformed twisted.

17.	Reinstall the steering gearbox.

18.	Check the wheel alignment.