Reassembly

NOTE:
- Clean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a solvent.
- Always replace the O-rings and rubber seals with new ones before assembly.
- Apply recommended power steering fluid to the parts indicated in the assembly procedures.
- Do not allow dust, dirt, or other foreign materials to enter the power steering system.
- Use the appropriate special tools where necessary.





Valve Body Unit Reassembly
1. Apply vinyl tape to the stepped portion of the pinion shaft, and coat the surface of the vinyl tape with the Dower steering fluid.
2. Install the backup ring with its tapered side as shown above.
3. Coat the inside surface of the new valve oil seal with power steering fluid.
4. Slide the valve oil seal over the pinion shaft, being careful not to damage the sealing lip.

CAUTION: Install the valve oil seal with its grooved side facing opposite the bearing.





5. Apply vinyl tape to the splines and stepped portion of the shaft, and coat the surface of the vinyl tape with the power steering fluid.
6. Fit the new O-ring in the groove of the pinion shaft. Then slide the new valve seal ring over the shaft and in the groove on the pinion shaft.
7. Remove the vinyl tape from the pinion shaft.
8. Apply power steering fluid to the surface of the valve seal ring that was installed on the pinion shaft.





9. Apply power steering fluid to the inside of the special tool. Set the larger diameter end of the special tool over the valve seal ring.
10. Move the special tool up and down several times to make the valve seal ring fit in the pinion shaft.
11. Remove the special tool.
12. Turn the special tool over, and set the smaller diameter end of the special tool over the valve seal ring. Move the special tool up and down several times to make the valve seal ring fit snugly in the pinion shaft.
13. Apply power steering fluid to the surface of the special tool. Set the new seal rings over the special tool from the smaller diameter end of the tool, and expand the seal rings. Do two rings at a time from each end of the sleeve.

NOTE:
- Do not over-expand the seal ring. Install the resin seal rings with care so as not to damage them. After installation, be sure to contract the seal rings using the special tool (sizing tool).
- There are two types of sleeve seal rings: black and brown. Do not mix the different types of sleeve seal rings as they are not compatible.





14. Set the special tool in the grooves in the sleeve, and set each ring in each groove securely.

NOTE: After installation, compress the seal rings with your fingers temporarily.





15. Apply power steering fluid to the seal rings on the sleeve, and to the entire inside surface of the special tool.
16. Insert the sleeve into the special tool slowly.
17. Move the sleeve each direction several times to make the seal rings snugly fit in the sleeve.

NOTE: Be sure that the seal rings are not turned up.





18. Apply power steering fluid to the surface of the pinion shaft. Assemble the sleeve over the pinion shaft by aligning the locating pin on the inside of the sleeve with the cutout in the shaft. Then. install the new circlip securely in the pinion shaft groove.

NOTE:
- Be careful not to damage the valve seal ring when inserting the sleeve.
- Install the circlip with its radiused side facing in.





19. Apply power steering fluid to the seal ring lip of the valve oil seal, then install the seal in the valve housing using a hydraulic press and special tools as shown.

CAUTION: Install the valve oil seal with its grooved side facing the tool.





20. Press the new roller bearing into the valve housing using a hydraulic press and special tools as shown.

NOTE: Place the roller bearing on the valve housing with the stamped letter facing up towards the valve side.





21. Apply vinyl tape to the pinion shaft, then coat the vinyl tape with power steering fluid.
22. Insert the pinion shaft into the valve housing.

CAUTION: Be careful not to damage the valve seal rings.

23. Remove the vinyl tape from the pinion shaft.





24. Press the pinion shaft/sleeve into the valve housing using a hydraulic press as shown.

NOTE: Check that the pinion shaft/sleeve turns smoothly by turning the pinion shaft with your hand.

Steering Rack Reassembly
25. Coat the piston seal ring guide with power steering fluid, and slide it onto the rack, big end first.
26. Position the new O-ring and new piston seal ring on the special tool, then slide them down toward the big end of the tool.

NOTE:
- Do not over expand the resin seal rings. Install the resin seal rings with care so as not to damage them. After installation, be sure to contract the seal ring using the special tool (sizing tool).
- Replace piston's O-ring and seal ring as a set.





27. Pull the O-ring off into the piston groove, then pull the piston seal ring off into the piston groove on top of the O-ring.
28. Coat the piston seal ring and the inside of the special tool with power steering fluid.
29. Carefully slide the tool onto the rack and over the piston seal ring.





30. Move the special tool back and forth several times to make the piston seal ring fit snugly in the piston.
31. Coat the sliding surface of the special tool and new cylinder end seal with power steering fluid.





32. Place the seal on the special tool with its grooved side facing opposite the special tool.





33. Apply a thin coat of grease to the inside of the special tool, and install it on the steering rack.

CAUTION: Make sure the rack teeth do not face the slot in the special tool.





34. Separate the cylinder end seal from the special tool, then remove the tool from the steering rack.





35. Install the new backup ring on the steering rack, then place the cylinder end seal to piston.





36. Grease the steering rack teeth, then insert the steering rack into the gear housing.

CAUTION: Be careful not to damage to inner surface of the cylinder housing with the rack edges.

37. Install the flange bolt into the end of the steering rack until it bottoms in the hole, then back the flange bolt out 1/4 turn. Hold the flange bolt and tighten the flange nut against the rack by hand.





38. Install the cylinder and seal into the bottom of the cylinder by pressing on the bolt with a press as shown.

CAUTION: Do not push on the bolt with excessive force as it may damage the cylinder end seal.

39. Remove the flange bolt, and center the steering rack.
40. Install the special tool onto the end of the steering rack, then coat the special tool with power steering fluid.
41. Coat the inside surface of the new cylinder end seal with power steering fluid.
42. Install the cylinder end seal onto the steering rack with its grooved side toward the piston.





43. Remove the special tool. Push in the cylinder end seal with your finger.

NOTE: Take care not to damage the cylinder end seal with the threads and burrs at the staked position of the gearbox.





44. Install a puller yoke to the gearbox housing, then clamp the puller yoke in a vise with son jaws as shown.

CAUTION: Do not clamp the cylinder.

45. Grease the inside surface of the cylinder end, then install the cylinder end into the cylinder and tighten it to the specified torque.
46. Remove the puller yoke from the gearbox housing.





47. Stake the point of the cylinder.

NOTE: Stake the cylinder in the position opposite from where the stake was removed during disassembly.

48. Select the 32 mm shim(s).

NOTE: Only reinstall the original 32 mm shim(s) when the steering gearbox is reassembled without replacing the pinion shaft, valve housing, and gear box housing with new ones. If the pinion shaft, valve housing, and gearbox housing are replaced, select the new shim(s) as follows.

Shim Selection:

a. Set the four 32 mm shims on the bearing surface of the gearbox housing. Total thickness of the four shims should equal no more than 0.70 mm. Shim set: four 32 mm shims (Thickness: 0.10 mm, 0.15 mm, 0.20 mm, 0.25 mm respectively). The four 32 mm shims do not have thickness identification marks. Measure the thickness of each shim using a micrometer, and mark the shim for identification.





b. Install the valve body unit on the gearbox, and tighten the flange bolts to the specified torque.





c. Measure the clearance between the gearbox and valve body unit using a feeler gauge as shown.

NOTE: Measure the clearance at the point midway between the two mounting bolts.

d. Determine the required thickness of the 32 mm shims by subtracting the clearance obtained in step c. from the total thickness of the four shims. (Total thickness of the 4 shims) - (Clearance) = Required thickness of the shims.

NOTE: Select the shims so that the total thickness is close to, but less than the required thickness.

Example: Measurement is 0.28 mm (0.011 inch): 0.70 - 0.28 = 0.42 mm (0.028 - 0.011 = 0.017 inch).

The selected shims should be 0.25 mm (0.010 inch) and 0.15 mm (0.006 inch) in thickness.

If the required shim thickness is 0.10 mm or less, no shims are necessary.





49. Set the selected 32 mm shims on the bearing surface of the gearbox housing.
50. Coat the new O-ring with grease, and carefully fit it on the valve housing.
51. Apply grease to the needle bearing in the gearbox housing.
52. Install the valve body unit on the gearbox housing by engaging the gears.

NOTE: Note the valve body unit installation position (direction of line connection).

53. Tighten the flange bolts to the specified torque.





54. Install the cylinder lines A and B.

NOTE:
- Clean the joints of the cylinder lines A and B thoroughly. The joints must be free of foreign material.
- Install the cylinder lines A and B by fighting the flare nuts by hand first, then tighten the flare nuts to the specified torque.





55. Grease the sliding surface of the rack guide, and install it onto the gearbox housing.
56. Apply a thin coat of grease to the new O-ring, and install it on the rack guide screw.
57. Install the spring, rack guide screw and locknut on the gearbox housing.
58. Adjust the rack guide screw.

NOTE: After adjusting, check that the rack moves smoothly by sliding the rack right and left.





59. Install the stop washer with the chamfered side facing out.
60. Screw each rack end into the rack while holding the new lock washer so its tabs are in the slots in the end of the rack.
61. Tighten the rack end securely.





62. Bend the lock washer back against the flat spots on the flange as shown.
63. Apply grease to the rack end joint housing.





64. Coat the rack end groove with silicone grease.





65. Install the boots in the rack end with the tube clamps.

NOTE:
- Install the boots with the rack in the straight ahead position fright and led tie-rods are equal in length).
- To ease boot installation, apply a thin coat of the grease to both ends of the boot.





66. Adjust the air hose fitting position of the boots by turning it as shown below.





67. Connect the air tube between the right and left boot, then install the clips on the cylinder line B as shown.





68. Install new boot bands on the boot and bend both sets of locking tabs.
69. Lightly tap on the doubled-over portions to reduce their height.

CAUTION: Stake the band locking tabs firmly.

70. Slide the rack right and left to be certain that the boots are not deformed or twisted.