Rack and Pinion Disassembly

Tools Required 

1. KM-J-22610 Installer

1. Remove the rack and pinion steering assembly from the vehicle. Refer to Rack and Pinion Assembly Removal  .
2. Remove the valve and pinion assembly from the rack and pinion steering assembly. Refer to Rack and Pinion Assembly Removal 
3. Remove the rack bearing assembly from the rack and pinion steering assembly. Refer to Rack Bearing Preload Adjustment  .
4. Mark the threads on the inner tie rod to aid in repositioning the adjusting nut.
5. Loosen the adjusting nut and remove the outer tie rod nut and the adjusting nut.
Fig 1: Removing Outer Tie Rod Nut & Adjusting Nut
Courtesy of SUZUKI OF AMERICA CORP.
6. Remove the dust boot retaining clamps and remove the dust boot.
Fig 2: Removing Dust Boot Retaining Clamps
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7. Remove the inner tie rod.
Fig 3: Removing Inner Tie Rod
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8. Remove the adjuster plug lock nut, adjuster plug, adjuster spring and rack bearing.
Fig 4: Removing Adjuster Plug Lock Nut
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9. Remove the dust cover, snap ring and pinion lock nut. The pinion lock nut can be removed when the pinion shaft is fixed.
Fig 5: Removing Dust Cover
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10. Remove the dust cover (Rubber) and snap ring.
Fig 6: Removing Dust Cover (Rubber) & Snap Ring
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11. Remove the pinion gear and valve assembly by tapping on the pinion shaft gently with a hammer and steel bar.
Fig 7: Removing Pinion Gear
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12. Remove the pinion shaft seal and middle bearing.
Fig 8: Removing Pinion Shaft Seal & Riddle Bearing
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13. Remove the pinion shaft ball bearing by tapping on the pinion shaft gently with a rubber hammer and steel bar.
Fig 9: Removing Pinion Shaft Ball Bearing
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14. To remove the steering rack gear, remove the circlip from the rack gear housing.
Fig 10: Removing Circlip From Rack Gear Housing
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15. Pull out the rack gear and rack gear stopper at the same time from the rack gear housing.

Fig 11: Pulling Rack Gear & Rack Gear Stopper

Courtesy of SUZUKI OF AMERICA CORP.