Rack and Pinion Disassembly

Tools Required 

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 And 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 Using Plier

   Courtesy of SUZUKI OF AMERICA CORP.
7. Remove the inner tie rod.
   Fig 3: Removing Inner Tie Rod

   Courtesy of SUZUKI OF AMERICA CORP.
8. Remove the adjuster plug lock nut, adjuster plug, adjuster spring and rack bearing.
   Fig 4: Removing Adjuster Plug Lock Nut Adjuster Plug Adjuster Spring And Rack Bearing

   Courtesy of SUZUKI OF AMERICA CORP.
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 Snap Ring And Pinion Lock Nut

   Courtesy of SUZUKI OF AMERICA CORP.
10. Remove the dust cover (Rubber) and snap ring.
    Fig 6: Removing Dust Cover And Snap Ring

    Courtesy of SUZUKI OF AMERICA CORP.
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 By Tapping Pinion Shaft Gently With Hammer And Steel Bar

    Courtesy of SUZUKI OF AMERICA CORP.
12. Remove the pinion shaft seal and niddle bearing.
    Fig 8: Removing Pinion Shaft Seal And Niddle Bearing

    Courtesy of SUZUKI OF AMERICA CORP.
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 Tapping Pinion Shaft With Rubber Hammer And Steel Bar

    Courtesy of SUZUKI OF AMERICA CORP.
14. To remove the steering rack gear, remove the circlip from the rack gear housing.
    Fig 10: Removing Circlip From Rack Gear Housing

    Courtesy of SUZUKI OF AMERICA CORP.
15. Pull out the rack gear and rack gear stopper at the same time from the rack gear housing.
    Fig 11: Pulling Out Rack Gear And Rack Gear Stopper From Rack Gear Housing

    Courtesy of SUZUKI OF AMERICA CORP.