Disassembly and Reassembly
RACK AND PINIONTools Required
KM-J-22610 Installer
Disassembly Procedure
1. Remove the rack and pinion steering assembly from the vehicle.
2. Remove the valve and pinion assembly from the rack and pinion steering assembly.
3. Remove the rack bearing assembly from the rack and pinion steering assembly.
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.
6. Remove the dust boot retaining clamps.
7. Remove the dust boot.
8. Push back the plastic retainer protecting the connection between the inner tie rod and the power steering gear rack.
9. Counterhold the pinion-side inner tie rod and remove the cylinder-side inner tie rod.
10. Place a rag over the rack, counterhold the rack assembly on the teeth with a wrench, and remove the pinion-side inner tie rod.
IMPORTANT: The retaining ring can be released by inserting a small screwdriver through the hole in the side of the housing.
11. Remove the bulkhead inner cylinder retaining ring the bulkhead inner cylinder and the rack.
Assembly Procedure
NOTICE: Coat all the seals with power steering fluid to ensure proper sealing.
1. Install the rack, the bulkhead inner cylinder and the bulkhead inner cylinder retaining ring.
NOTICE: To prevent the inner tie rods from loosening, use Loctite 242 (or equivalent) on both inner tie rod connections to secure them to the rack shaft.
IMPORTANT: The right and left inner tie rods are unequal in length. Be sure to install the correct inner tie rod on the proper side of the power steering gear.
2. Firmly seat the inner tie rods against the rack and tighten both ends simultaneously.
Tighten
Tighten the inner tie rods to 100 Nm (74 ft. lbs.).
3. Push the plastic retainer back onto the connection between the inner tie rod and the power steering gear rack.
4. Install the dust boot.
5. Install the cylinder end dust boot retaining clamps with the installer KM-J-22610.
6. Install the tie rod end boot retaining clamps.
7. Reposition the adjusting nut to the marks on the inner tie rod and install the outer tie rod by twisting it onto the inner tie rod.
8. Perform a front toe adjustment.
9. Tighten the adjusting nut.
Tighten
Tighten the outer tie rod adjusting nut to 22 Nm (16 ft. lbs.)
10. Install the rack bearing assembly into the rack and pinion steering assembly.
11. Install the valve and pinion assembly into the rack and pinion steering assembly.
12. Install the rack and pinion steering assembly into the vehicle.
STUB SHAFT SEALS AND UPPER AND LOWER BEARING
Disassembly Procedure
1. Remove the rack and pinion steering assembly from the vehicle.
2. Remove the dust cover from the lower end of the housing.
NOTICE: If the stub shaft is not held, damage to the pinion teeth will occur.
3. While holding the stub shaft with a wrench, remove the locknut from the pinion.
4. With the gear centered, mark the location of the stub shaft notch on the housing to aid in properly installing the valve and pinion assembly.
5. Remove the stub shaft retaining ring and, using an arbor press, press on the threaded end of the pinion until it is possible to remove the pinion and valve assembly from the housing.
6. Remove the stub shaft dust seal the stub shaft bearing annulus assembly and the valve assembly from the housing. Discard the stub shaft dust seal.
7. Remove the lower valve assembly bearing and the bushing.
8. Remove the lower bearing assembly retaining ring and press the lower bearing assembly from the lower end of the housing.
Assembly Procedure
NOTICE: Coat all the seals with power steering fluid to ensure proper sealing.
1. Install the lower bearing assembly and the lower bearing assembly retaining ring into the lower end of the housing.
2. Install the lower valve assembly bearing and the bushing.
3. Center the rack in the housing.
4. Install the valve assembly, the stub shaft bearing annulus assembly and a new stub shaft dust seal into the housing.
IMPORTANT: When the valve and pinion assembly is fully seated in the housing, be sure that the notch in the stub shaft and the mark on the housing line up.
NOTICE: If the stub shaft is not held, damage to the pinion teeth will occur.
5. While holding the stub shaft, install the locknut onto the pinion shaft.
Tighten
Tighten the pinion locknut to 30 Nm (22 ft. lbs.).
6. Replace the dust cover onto the housing.
7. Install the rack and pinion steering assembly.
RACK BEARING
Tools Required
J-35423 Rack Guide Spring Cap Wrench
Disassembly Procedure
1. Remove the rack and pinion steering assembly from the vehicle.
2. Remove the adjuster plug locknut from the adjuster plug, and remove the adjuster plug from the housing with the rack guide spring cap wrench J-35423, or with a 19 mm allen wrench.
3. Remove the adjuster spring and the rack bearing.
Assembly Procedure
1. Coat the rack bearing, the adjuster spring and the adjuster plug with lithium-based grease and install them into the housing.
2. With the rack centered, turn the adjuster plug clockwise until a torque of 5 Nm (44 inch lbs.) is obtained, then back it off by 30 to 40 degrees. Check the pinion torque.
Maximum pinion preloaded torque is 1 Nm (9 inch lbs.).
3. Thread the locknut on the adjuster plug and tighten it.
Tighten
Tighten the adjuster plug locknut to 70 Nm (52 ft. lbs.) while holding the adjuster plug stationary with the rack guide spring cap wrench J-35423 or with a 19 mm allen wrench.
4. Install the rack and pinion assembly.
RACK BEARING PRELOAD ADJUSTMENT
Adjustment Procedure
1. Raise and suitably support the vehicle.
2. Center the steering wheel.
3. Remove the power steering gear.
4. Loosen the locknut and turn the adjuster plug clockwise until a torque of 5 Nm (44 inch lbs.) is obtained, then loosen it by 30 to 40 degrees.
5. Tighten the locknut on the adjuster plug while holding the adjuster plug stationary.
Tighten
Tighten the adjuster plug locknut to 70 Nm (52 ft. lbs.).
6. Install the power steering gear.
7. Be sure to check the returnability of the steering wheel to center position after adjustment.
VALVE AND PINION
Disassembly Procedure
1. Remove the rack and pinion steering assembly from the vehicle.
2. Remove the dust cover from the lower end of the housing.
NOTICE: If the stub shaft is not held, damage to the pinion teeth will occur.
3. While holding the stub shaft, remove the locknut from the pinion.
4. With the gear centered, mark the location of the stub shaft notch on the housing to aid in properly installing the pinion and valve assembly.
5. Remove the upper housing retaining ring and, using an arbor press, press on the threaded end of the pinion until it is possible to remove the valve and pinion assembly from the housing.
6. Remove the stub shaft dust seal, the stub shaft bearing annulus assembly and the valve and pinion assembly from the housing.
7. Inspect the valve body rings for wear or damage. Replace the valve body rings as needed. Coat the rings with power steering fluid before installation.
8. Remove the lower pinion valve seal and bushing. Discard the seal.
Assembly Procedure
NOTICE: Coat all of the seals and bushings with power steering fluid to ensure proper sealing.
1. Install the bushing and a new lower pinion valve seal.
IMPORTANT: When the valve and pinion assembly is fully seated in the housing, be sure the notch in the stub shaft and the mark on the housing line up. If this is not done the vehicle will not pass the straight-ahead check and will have poor steering performance.
2. Install the valve and pinion assembly, the stub shaft bearing annulus assembly and the stub shaft dust seal.
NOTICE: If the stub shaft is not held, damage to the pinion teeth will occur.
3. While holding the stub shaft, tighten the locknut onto the pinion shaft.
Tighten
Tighten the pinion locknut to 30 Nm (22 ft. lbs.).
4. Replace the dust cover onto the housing.
5. Install the rack and pinion steering assembly.
6. Perform the straight-ahead check.