Power steering rack - ’d’ series (page 3 of 3)

23. Position container beneath steering rack.
24. Loosen steering rack feed and return pipe unions.

25. Remove 2 bolts securing steering rack clamp and remove clamp.
26. Remove 2 bolts and plain washers securing steering rack flange to front beam.
27. Move steering rack to driver’s side sufficiently to release feed and return pipes from rack.

CAUTION: Plug the connections.

28. Tie pipes aside, clear of pinion housing.
29. Lower steering rack sufficiently to release pinion shaft from body aperture.

30. Remove pinion shaft seal.
31. Lower and rotate rack until pinion faces downwards and move rack to passenger’s side to clear tie-rod.
32. Manoeuvre and remove rack from driver’s side. Do not carry out further dismantling if component is removed for access only.
33. Remove clamp rubber, 2 collars and 4 mounting bushes and fit to new rack.

Refit

1. Ensure body aperture seal is seated correctly on flange.
2. Extend rack fully to passenger’s side.
3. With rack pinion facing downwards, feed rack in far enough to passenger’s side for pinion end tie-rod to clear front beam. Rotate and locate rack into position.
4. Fit pinion shaft seal.

CAUTION: Ensure slot in seal is located to tab on pinion housing.

5. Raise rack and locate pinion through body aperture.

CAUTION: Take care not to dislodge aperture seal.

6. Clean feed and return pipe unions, connect pipes and unions in pinion housing.
7. Align rack and fit bolts and plain washers to pinion flange, DO NOT tighten.
8. Fit clamp rubber and clamp, tighten bolts to 38 Nm.Tighten bolts securing pinion flange end to 58 Nm.
9. Raise engine and gearbox assembly, fit centre engine mounting nuts and tighten to 64 Nm.