DISASSEMBLY
| DISASSEMBLY |
| Saab 9-2X 2.5i Linear |
RACK HOUSING ASSEMBLY
Disconnect the four pipes from gearbox.| Note | ||
|
Remove the pipes E and F as a single unit being fixed at clamp plate. |
Secure the gearbox removed from vehicle in vice using ST.
ST 32005190 STAND
| Important | ||
|
Secure the gearbox in a vise using ST as shown. Do not attempt to secure it without this ST. |
||
Remove the tie-rod end and lock nut from gearbox.
Remove the small clip from boot using pliers, and then move the boot to tie-rod end side.
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(1)
|
Clip
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Using a flat tip screwdriver, remove the band from boot.
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(1)
|
Band
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Extend the rack approx. 40 mm (1.57 in) out. Unlock the lock washer on both side of tie-rod end using a flat tip screwdriver.
| Important | ||
|
Be careful not to scratch the rack surface as oil leaks may result. |
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(1)
|
Lock washer
|
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(2)
|
Approx.
40 mm (1.57 in)
|
Using the ST, loosen the lock nut.
ST 32005191 SPANNER
Tighten the adjusting screw until it no longer tightens.
Using a wrench [32 mm (1.26 in) width across flats] or adjustable wrench, remove the tie-rod.
Loosen the adjusting screw, and then remove the spring and sleeve.
Remove the two bolts securing valve assembly.
Carefully draw out the input shaft, and then remove the valve assembly.
Using a sharp pointed pliers, rotate the rack stopper in direction of the arrow until end of the circlip comes out of stopper. Rotate the circlip in opposite direction and pull it out.
|
(1)
|
Rack stopper
|
Pull the rack assembly from cylinder side, and draw out the rack bushing and rack stopper together with the rack assembly.
| Important | ||
|
Be careful not to contact the rack to inner wall of cylinder when drawing out. Any scratch on the cylinder inner wall will cause oil leakage. |
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(1)
|
Rack bushing
|
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(2)
|
Rack assembly
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(3)
|
Rack stopper
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Remove the rack bushing and rack stopper from rack assembly.
Remove the oil seal from rack.
Insert the ST from pinion housing side, and then remove the oil seal using a press.
ST 32005053 REMOVER
|
(1)
|
Press
|
|
(2)
|
Oil seal
|
CONTROL VALVE ASSEMBLY
Disconnect the four pipes from gearbox.| Note | ||
|
Remove the pipes E and F as a single unit being fixed at clamp plate. |
Secure the gearbox removed from the vehicle in vise using ST.
ST 32005190 STAND
| Important | ||
|
Secure the gearbox in a vise using ST as shown. Do not attempt to secure it without this ST. |
||
Using the ST, loosen the lock nut.
ST 32005191 SPANNER
Tighten the adjusting screw until it no longer tightens.
Loosen the adjusting screw, and then remove the spring and sleeve.
Remove the two bolts securing valve assembly.
Carefully draw out the input shaft, and then remove the valve assembly.
Slide the dust cover out.
|
(1)
|
Dust cover
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Using a press remove the pinion and valve assembly from valve housing.
|
(1)
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Valve assembly
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(2)
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Valve housing
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(3)
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Cloth
|
Using the ST and press, remove the dust seal, oil seal and special bearing from valve housing.
ST 32005047 INSTALLER & REMOVER SEAL
| Important | ||
| • |
Do not apply force to the end
surface of valve housing.
|
|
| • |
Do not reuse the oil seal after removal.
|
|
|
(1)
|
Oil seal
|
|
(2)
|
Special
bearing
|
Remove the snap ring using snap ring pliers.
| Important | ||
|
Be careful not to scratch the pinion and valve assembly. |
||
Press out the bearing together with the back up washer using pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555 in) and press.
|
(1)
|
Bearing
|
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(2)
|
Backing
washer
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(3)
|
Oil seal
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(4)
|
Pipe
|
Remove the oil seal.
| Saab 9-2X 2.0T Aero |
Secure the gearbox removed from vehicle in vise using the ST.
ST 32005190 STAND
| Important | ||
|
Secure the gearbox assembly in a vise using the ST as shown. Do not attempt to secure it without this ST. |
||
|
(1)
|
Clamp
|
Remove the tie-rod end and lock nut from gearbox.
Remove the clip on outside of boot using pliers, and then slide the boot to tie-rod end side.
|
(1)
|
Clip
|
Using flat tip screwdriver, remove the band from boot.
| Note | ||
|
Check the boot for crack, damage or deterioration. |
||
|
Replace the boot with a new one if necessary. |
|
(1)
|
Band
|
Using the ST, loosen lock nut.
ST 32005191 SPANNER
|
(1)
|
Lock nut
|
Tighten the adjusting screw until it no longer tightens.
Using a wrench (32 mm (1.26 in) width across flats) or adjustable wrench with cinching boot, remove the tie-rod.
|
(1)
|
Tie-rod
|
Loosen the adjusting screw, and then remove the spring and sleeve.
Disconnect the pipes A and B from steering body and control valve housing.
|
(1)
|
Pipe
A
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|
(2)
|
Pipe B
|
Clean the dirt of input shaft. Remove the dust cover taking care not to scratch the housing or input shaft and allow foreign matter to enter gear box interior.
|
(1)
|
Dust cover
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Align the ST pin to plug hole to install. Rotate the ST counterclockwise to remove plug.
ST 32009456 PLUG WRENCH
|
(1)
|
Plug
|
Remove the valve assembly taking care not to scratch seal ring and valve housing inner surface.
|
(1)
|
Valve
ASSY
|
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(2)
|
Seal ring
|
Remove the holder using a wrench (36 mm (1.42 in) width across flats) or adjustable wrench.
Install the ST on valve side of rack and press outer side oil seal out taking care not to contact rack with steering body inner surface.
ST 32009554 INSTALLER & REMOVER
| Note | ||
|
Block the pipe connection of steering body to prevent fluid from flowing out. |
|
(1)
|
Rack
piston
|
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(2)
|
Outer side
oil seal
|
Insert the ST from valve side and press back-up ring and oil seal out.
ST 32009461 REMOVER
Using the ST1 and ST2, repair the cylinder’s clinched sections.
ST1 32009455 PUNCH
ST2 32009462 BASE
|
(1)
|
Cylinder
|
If the cylinder edge is deformed in a convex shape, repair using an oil stone.
Remove the oil seal using ST and press from plug.
ST 32009457 PLUG OIL SEAL REMOVER
| Note | ||
|
Do not apply force on the plug edge surface. |
|
(1)
|
Oil
seal
|
|
(2)
|
O-ring
|
Set the ST on drawing dimension.
ST 32009459 GEARBOX OIL SEAL REMOVER
|
(1)
|
70 mm (2.76
in)
|
Set the stopper to gear box, and then insert the tip of ST to gear box.
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(1)
|
Stopper
|
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(2)
|
Oil seal
|
By fixing the 2-surface width, press in by rotating the rod and attach to oil seal.
|
(1)
|
Rod
|
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(2)
|
2-surface
width
|
While fixing the 2-surface width, pull out the oil seal by rotating nut.
| Important | ||
|
Take care not to scratch the gear box inner surface. |
||
|
(1)
|
2-surface
width
|
|
(2)
|
Nut
|
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