Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 2036

3B-34  STEERING

POWER STEERING UNIT

REPAIR KIT

1. Nut : adjust screw
2. Gasket : cover
3. Gasket : sector shaft
4. Seal : sector shaft
5. Gasket : housing
6. Ring : retaining

7. Ring : seal
8. Seal: oil
9. Gasket : housing

10. Gasket : housing
11. Seal ring : housing

STEERING  3B-35

  DISASSEMBLY

Disassembly Steps

1. Retaining ring
2. Seal ring

V

3. Oil seal

V

4. Lock nut

V

5. Top cover assembly
6. O-ring
7. Needle bearing

V

8. Sector shaft

V

9. Ball nut and valve housing assembly

10. Gasket
11. Seal ring
12. Gasket
13. Needle bearing
14. Sector shaft seal
15. Sector shaft gasket
16. Gear box

3B-36  STEERING

Important Operations

Avoid clamping the steering gear assembly in a vise by the
power cylinder housing.

3. Oil Seal

(1) Clean the faces of the extended stub shaft.

(2) Plug the hose fitting on the inlet side.

(3) Remove the oil seal by blowing compressed air through the

hole in the outlet side.

4. Lock Nut
Remove the adjusting screw lock nut and turn the adjusting
screw counter-clockwise to remove the preload between the
sector gear and the rack piston, then remove the top cover
bolts.

5. Top Cover
Hold the top cover stationary, turn the adjusting screw
clockwise to raise and free the cover, then remove the cover.

8. Sector Shaft
Bring the stub shaft into straight-ahead position.
Do not force the sector shaft off the gear box with a hammer or
other impact tools.

STEERING  3B-37

9. Ball Screw and Valve Housing Assembly
It is strongly advisable to keep the ball nut and valve housing
assembly always in a horizontal position, or the rack piston will
fall off onto the end of the worm, causing the rack piston to slip
out of the worm shaft and the balls to fall out.

  INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found
through inspection.

•

 Bearing

•

 Oil seal, Dust seal, Dust cover

•

 O-Ring, seal ring

•

 Ball nut and valve housing

•

 Sector shaft

•

 Gear box

Visual Check

Inspect the following parts for wear, damage or other abnormal
conditions.

Ball-Nut Rotation

Hold the ball nut and valve housing assembly vertically and see
if the ball-nut lowers by turning smoothly.  If the lowering of the
ball-nut by its own weight is not smooth, check the worm shaft
for bending and the ball-groove for burrs, dents and foreign
matter.
Note :
When testing the ball nut and valve housing assembly, do
not let it travel all the way to the end of worm shaft, or
damage to the ball tubes will result.

Sector shaft outside diameter

mm (in)

Standard

Limit

32.0 (1.260)

31.97 (1.258)