Montero 4WD L4-2555cc 2.6L SOHC (1984)
7.
Remove seal ring and O-rings from valve housing and rack piston.
8.
Remove valve housing top cover using tool MP990853.
9.
Remove ball bearing and oil seal from top cover.
10.
Remove oil seal and U-packing from gear housing. Do not disassemble the needle bearing.
Assembly
1.
Apply suitable grease to bearing surface of side cover needle bearing and install the 33 rollers.
2.
Apply suitable grease to bottom of side cover, then position new O-ring on the cover.
3.
Install adjusting bolt and plate into slot on top of cross shaft. Install plate with chamfered side toward cross shaft mating surface.
4.
Adjust cross shaft endplay to 0-.002 inch, using spacers as necessary.
5.
Install side cover onto cross shaft and tighten with adjusting bolt, then tighten locknut temporarily.
6.
Apply thin coat of suitable grease to gear housing U-packing and oil seal, then press them into housing using tools MB990938 and MB990926, or
equivalent.
7.
Apply thin coat of suitable grease to lip of valve housing oil seal, then press it into housing.
8.
Press ball bearing into top cover, then install thrust plate, needle roller bearing and second thrust plate into cover. Install thinner of the two
thrust plates on top cover side.
9.
Install and temporarily tighten the top cover.
10.
Using tool MB990853 and a spring scale, tighten top cover to a force of 14-19 lbs., then loosen top cover until torque becomes 0 ft. lbs. Rotate
input worm shaft and check for smooth operation.
11.
Measure starting torque using tool MB990228, while turning input worm shaft, and note the value.
12.
Tighten top cover until starting torque of input worm shaft is 1.8-2.7 inch lbs. more than value measured in step 11.
13.
Install valve housing nut and torque to 131-166 ft. lbs.
14.
Remeasure starting torque while turning input worm shaft. Preload should measure 2-6 inch lbs. If not, loosen valve housing nut and repeat steps
10 through 12.
15.
Secure gear housing in a vise and install screw unit.
16.
Install valve housing attaching bolts and torque to 33-39 ft. lbs. Rotate input worm shaft to move rack piston to the neutral position.
17.
Install cross shaft with side cover to gear housing. Torque attaching bolts to 33-39 ft. lbs. When installing cross shaft assembly, take the following
precautions:
a. Apply thin coat of automatic transmission fluid to rack piston teeth and shaft.
b. Apply suitable grease to lip of oil seal.
c. Do not rotate side cover when installing to prevent damage to O-ring.
d. Wrap the serration of cross shaft with vinyl tape and install it carefully to avoid damaging the seal.
18.
Measure total starting torque of input worm shaft, in the neutral position, and adjust as necessary to 4-8 inch lbs. Ensure that screw unit operates
smoothly throughout its entire range.
19.
Connect cross shaft to pitman arm. Ensure that slit on tip of shaft is aligned with mark on pitman arm and torque retaining nut to 94-108 ft. lbs.
