Remove four mounting bolts of steering rack 6. and pinion assembly from Steering Gear Mounting Panel. Take out steering rack and pinion assembly 7. from either side of steering knuckle. INSPECTION Remove rubber seal from the steering rack and 1. pinion assembly and inspect the condition of rubber seal i.e. for any cut or damage. Replace rubber seal if found damaged. Inspect steering rack for any external damage. 2. Replace damaged or worn out parts. Check condition of tie rod ball joint. If found 3. cracked or excessive play, replace ball joint. Replace tie rod ball joint nylon nut. 4. Check free rotating torque of pinion shaft. If 5. found jammed, replace steering rack assembly. Inspect rubber bellows for any rupture INSTALLATION Fit rubber seal on steering rack assembly. 1. Insert steering rack and pinion tie rod ends 2. through either side of steering knuckle. Tighten both tie rod ball joint nyloc nut to 3. specified torque. Tightening torque as per specified. Tighten upper universal joint bolt to specified 4. torque. Tightening torque as per specified. Tighten lower universal joint bolt to specified 5. torque. (Thus securing steering column with rack). Tightening torque as per specified. Mount spare wheel and tighten the knob. 6. Refit both front wheels. 7. Check for toe settings and do wheel alignment 8. if required. Refer wheel alignment procedure). NOTE Please ensure the correct fitment of rubber seal on steering rack assembly NOTE Wheel alignment is necessary after installation (Refer wheel alignment procedure). There is a poka-yoke provided at steering pinion to lower and upper universal joint (UJ) mounting. The UJ can be fitted in one direction only. If warning lamp is OFF and no heavy steering is observed, then ignore this DTC U1609-81. If warning lamp is OFF and heavy steering is observed, then check for other DTCs logged along with this DTC U1609-81. (Refer diagnostic tool user manual for trouble shooting. WARNING Do not reuse the OBJ nyloc nut. Do not reuse universal joint bolt. STEERING (MANDO) 18
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