Daewoo Matiz (2003 year). Manual - part 180

6D – 12  MANUAL STEERING GEAR

D105B704

D

Coat the greases on the tie rod (5).

D

Remove the rack and pinion boot (6).

D105B705

3. Remove the tie rod

D

Pull the rack gear perfectly from the steering gear
housing by turning the pinion gear (1).

D

Disconnect the shock damper ring from the tie rod
ball joint (2).

D15B706A

D

Vise the rack gear (3).

Important: Clothe the rack gear with a cloth before vis-
ing the rack gear.

Notice: Do not vise the rack gear over two teeth face.

D105B707

D

Remove the tie rod (4).

D

Remove the shock damper ring (5).

MANUAL STEERING GEAR  6D – 13

D105B708

4. Remove the rack bearing.

D

Remove the adjuster plug (1).

D

Remove the adjuster spring (2).

D105B709

5. Remove the pinion and bearing assembly.

D

Remove the dust cover (1).

D

Remove the pinion plug (2).

Important: Do not reuse the removed pinion plug.

D105B710

D

Remove the pinion and bearing assembly (3).

D105B711

6. Remove the rack gear toward the driver side of the

steering gear.

a. Rack gear.

Notice: Remove the rack gear toward the driver side of
the steering gear to prevent the bulk head in the steering
gear housing from damaging in installing and removing
the rack gear.

6D – 14  MANUAL STEERING GEAR

D105B712

Inspection Procedure

1. Inspect the rack gear deformation and damage.

D

Set the V–block on the plate (1).

D

Set the rack gear on the V–block (2).

D

Check the rack gear for deformation using a dial
gauge (3).

D

Inspect the rack gear for wear and damage (4).

D105B713

2. Inspect the pinion and bearing assembly damage.

D

Inspect the pinion gear for wear and damage (1).

D

Inspect the bearing for loose and operation (2).

D105B714

3. Inspect the tie rod end boot and the rack and pinion

boot for damage.

D

Inspect the tie rod end boot for crack and wear (1).

D

Inspect the rack and pinion boot for crack and wear
(2).

D105B715

4. Inspect the steering gear housing for crack, deforma-

tion and wear.

a. Steering gear housing.

MANUAL STEERING GEAR  6D – 15

D105B716

5. Inspect the tie rod end ball joint and tie rod ball joint

for damage.

D

Inspect the tie rod end ball joint for operation (1).

D

Inspect the tie rod ball joint for operation and tie rod
deformation (2).

6. After inspecting the parts, replace the defected parts.

D105B717

Assembly Procedure

Important: Coat the all turn, contact and rub surface
with grease.

1. Clean the all parts removed.

2. Install the rack gear.

D

Coat the rack gear with grease (1).

D

Insert the rack gear carefully (2).

D15B718A

3. Install the pinion and bearing assembly.

D

Set the rack in balance (1).

D

Coat the pinion and bearing assembly and steering
gear housing surface with grease.

D

Install the pinion and bearing assembly (2).

D

Coat the pinion plug with Loctitte.

D

Install the pinion plug (3).

Tighten

Tighten the pinion plug to 40–60 N

S

m (30–44 lb-ft).

D

Install the dust cover (4).

D105B719

4. Install the rack bearing.

D

Coat the rack bearing with grease.

D

Install the rack bearing (1).

D

Install the adjuster spring (2).

D

Tighten the adjuster plug softly (3).