Isuzu Trooper (2000 year). Manual - part 48

2A–22

POWER ASSISTED SYSTEM

Steering Gear Disassembled View

440RS001

Legend

(1) Dust Cover
(2) Retaining Ring
(3) Back Up Ring
(4) Oil Seal
(5) Ball-nut and Valve Housing Assembly
(6) O-ring

(7) Seal Ring
(8) O-ring
(9) Gear Box

(10) Sector Shaft

(11) Top Cover Assembly

(12) Lock Nut

POWER ASSISTED SYSTEM

2A–23

Disassembly

CAUTION: Do not clamp the steering gear assembly
in a vise by the power cylinder housing.

1. Remove dust cover.
2. Remove retaining ring.
3. Remove back up ring.
4. Remove oil seal.

D

Clean the faces of the extended stub shaft.

D

Plug the hose fitting on the inlet side.

D

Remove the oil seal by blowing compressed air
through the hole in the outlet side.

440RS002

5. Remove lock nut.

D

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.

6. Remove the top cover bolts and the top cover

assembly.

440RS003

D

Holding the top cover stationary, turn the adjusting
screw clockwise to raise and free to cover, then
remove the cover with O-ring.

7. 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 then remove sector
shaft.

440RS004

2A–24

POWER ASSISTED SYSTEM

8. Remove ball-nut and valve housing assembly.

440RS005

D

Always keep the ball nut and valve housing
assembly in a horizontal position to prevent them
from traveling to the end of the worm shaft and
damaging the ball tubes.

9. Remove O-ring.

10. Remove seal ring.

11. Remove O-ring.

12. Remove gear box.

Inspection and Repair

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

D

Bearing

D

Ball-nut and valve housing

D

Sector shaft

D

Top cover

D

Gear box

D

Needle bearing

D

Dust seal

D

Seal ring

D

Gasket

Ball-nut Rotation

440RS006

Hold the ball nut and valve housing assembly vertically
and see if the ball-nut lowers by turning smoothly.  If the
ball-nut does not lower smoothly, check the worm shaft
for bending 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.

D

Check sector shaft outside diameter.

Limit: 31.7 mm (1.25 in)

440RS007

POWER ASSISTED SYSTEM

2A–25

Dust Seal and Seal Ring Setting

440RW001

D

Note the dust seal (1) and the seal ring(2) installation
direction. Always install a new part.

D

Apply a thin coat of power steering fluid to lip of each
part.

Gasket Setting

440RW002

D

Note the gasket(1) installation direction.

D

Apply a thin coat of power steering fluid to lip of each
part.

Reassembly

1. Install gear box.
2. Apply a thin coat of power steering fluid to the new

O-ring(2) and be sure to discard used part, then install
o-ring.

3. Apply a thin coat of power steering fluid to the new

seal ring(1) and be sure to discard used part,  then
install seal ring.

4. Apply a thin coat of power steering fluid to the new

O-ring and be sure to discard used part, then install
o-ring.

440RS010

5. Install ball-nut and valve housing assembly.

D

Always keep the ball screw and valve housing
assembly in a horizontal position (avoid holding it
vertically), 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 ball to fall out.

440RS005

D

Be careful not to drop the O-ring into the valve
housing.

D

Tighten the valve housing bolts to the specified
torque.

Torque: 47 N·m (35 lb ft)