1. Tie rod end.
2. Tie rod end lock nut.
3. Small boot clamp.
4. Dust cover.
5. Large boot clamp.
6. Steering gear housing assembly.
Note.
: replace the part with a new one after each removal.
: Apply Molywhite LSG or equivalent.
Disassembly
1. Loosen the lock nut and remove the steering rod end.
2. Remove the boot clamps and boots from the inner parts of the steering rods.
Caution. Be careful not to damage the inner parts of the steering rods and the steering gear housing assembly when removing the dust boots. If damaged, the inner parts of the steering rods and the steering gear housing assembly must be replaced with new ones, since foreign particles may get inside the steering gear.
Checking after disassembly
Anthers
Check the dust boots for cracks. If any defects are found, replace the dust boot with a new one.
Steering gear housing
Check the steering gear housing for damage and scratches on the internal surfaces. If any defects are found, replace the housing with a new one.
Tie rod ends and inner parts
Perform the following checks and replace the relevant parts with new ones if the check results do not meet the specifications.
1. Check the moment of release of the ball joints:
Hook the spring dynamometer as shown in the figure and pull. Make sure that the spring dynamometer readings at the moment the ball joint pin begins to move correspond to the set values. If the obtained values do not correspond to the norm, replace the inner and outer ball joints with new ones.
Note: Standard values are given in the "Service Data and Specification" section at the end of the chapter.
2. Check the axial play of the ball joint pin:
Apply an axial load of 490 N (50 kgf) to the ball joint pin. Using a dial indicator, measure the amount of pin movement. Make sure the value obtained corresponds to the specified range. Replace the outer (1) or inner (2) ball joint if the measurement result does not correspond to the standard.
Assembly
1. Set the steering rack to the central position.
Note: Dimension L with steering rack in neutral position: 77.5 mm.
2. Install the dust boots on the steering gear housing and the inner parts of the steering rods.
3. Install the larger diameter boot clamps (1) onto the boot and tighten it using the special tool (A) (KV40107300).
Note: Install the large diameter boot clamp (1) securely into the boot groove, then tighten the clamp so that the gap shown in the figure does not exceed 3 mm.
4. Install small diameter clamps on the anthers.
5. Adjust the inner parts of the steering rods to the standard length "L" and tighten the lock nuts to the specified tightening torque. After tightening the lock nuts, check the length "L" again.
Caution: Adjust the toe-in of the steering wheels. The length set after adjustment does not necessarily correspond to the specifications.
Note: When tightening the lock nut, it is necessary to hold the tie rod end with a wrench or similar means to prevent the ball joint from contacting the steering knuckle!