Unit Overhaul

INSPECTION AND ADJUSTMENT PRIOR TO DISASSEMBLY





Mount the gear box in a soft jawed vise.

NOTE: Do not tighten the vise on the gear housing. Use the mounting section of the rack to secure it in the vise.

Total Pinion Preload





1. Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to confirm the total pinion preload.
Total pinion preload [Standard value] 0.6 - 1.3 Nm (6 - 13 kg-cm, 5.2 - 11.3 inch lbs.)

NOTE: Measure the pinion preload through the entire stroke of the rack.

2. If the measured value is out of specifications, first adjust the yoke plug, then re-check the total pinion preload.
3. If the yoke plug adjustment does not obtain the total pinion preload, check or replace the yoke plug components.

Tie Rod Swing Resistance
1. Give 10 hard swings to the tie rod.





2. Measure the tie rod swing resistance with a spring scale.
Tie rod swing resistance [Standard value] 8 - 22 N (1.9 - 4.6 lbs.) [2 - 5 Nm (20 - 50 kg-cm, 17 - 43 inch lbs.)]
3. If the measured value exceeds the standard value, replace the tie rod assembly.

NOTE: Even if the measured value is below the standard value, a tie rod that swings smoothly without excessive play may be used. If the measured value is below 4.3 N (0.9 lb.) [100 Ncm (8.7 inch lbs.)], replace the tie rod.

Bellows Inspection
1. Inspect the bellows for damage or deterioration.
2. Make sure the bellows are secured in the correct position.
3. If the bellows are defective, replace them.

DISASSEMBLY





1. Remove the tie rod end from the tie rod.





2. Remove the dust cover from the ball joint.





3. Remove the bellows band.





4. Remove the bellows clip.
5. Pull the bellows out toward the tie rod.

NOTE: Check for rust on the rack when the bellows are replaced.

6. Remove the feed tube from the gear housing.
7. While moving the rack slowly, drain the fluid from the gear housing.
8. Remove the end plug.





9. With the pinion turned clockwise until the rack is locked, remove the self-locking nut.





10. Unstake the tab washer between the tie rod and rack with a chisel.





11. Remove the tie rod from the rack.

NOTE: Remove the tie rod from the rack, taking care not to twist the rack.





12. Remove the yoke plug locking nut.





13. Using special tool, remove the yoke plug.





14. Remove the rack support spring, rack support yoke and bushing from the gear box.





15. Remove the valve body housing by loosening the two bolts.





16. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the gear housing.





17. When the end of the circlip comes out from the notched hole of the housing rack cylinder, turn the rack stopper counterclockwise and remove the circlip.





18. Remove the rack stopper, rack bushing and rack from the gear housing by moving it toward the pinion side.

NOTE: When the rack has been removed, be sure to replace the housing side oil seal.





19. Remove the O-ring from the rack bushing.





20. Remove the oil seal from the rack bushing.





21. Remove the valve body from valve body housing with a soft hammer.





22. Use the special tool to remove the oil seal and ball bearing from the valve body housing.





23. Use the special tool to remove the ball bearing from the gear housing.

NOTE: Be careful not to damage the pinion valve cylinder inside of the gear housing.





24. Use the special tool (09517-21400) to remove the needle bearing from the gear housing.





25. Use the special tools to remove the oil seal from the gear housing.

NOTE: Be careful not to damage the rack cylinder inside of the gear housing.

INSPECTION





1. Rack
1. Rack tooth face damage or wear
2. Oil seal contact surface damage
3. Rack distortion
4. Oil seal ring damage or wear
5. Oil seal damage or wear





2. Pinion Valve
1. Pinion gear tooth face damage or wear
2. Oil seal contact surface damage
3. Seal ring damage or wear
4. Oil seal damage or wear

3. Bearing
1. Seizure or abnormal noise during bearing rotation.
2. Excessive play.
3. Missing needle bearing

4. Others
1. Damage of the gear housing cylinder bore
2. Boot damage or deterioration

REASSEMBLY
1. Apply the specified oil to the entire surface of the rack oil seal.
Recommended fluid: PSF-3 type





2. Install the backup washer and oil seal to the specified position in the gear housing.
3. Apply the specified grease to the entire surface of the needle bearing.
Recommended grease: Multipurpose grease SAE J310, NLGI No.2





4. Set the scribed side of the needle bearing in the special tool and install it into the gear housing (until the special tool contacts the gear housing).

NOTE: Note the direction of the needle bearing.





5. Apply the specified grease to the ball bearing and install using the special tool.
Recommended grease: Multipurpose grease SAE J310, NLGI No.2

NOTE: Always use a new bearing

6. Apply the specified oil to the entire surface of the rack bushing oil seal.
Recommended fluid: PSF-3 type
7. Install the oil seal in the rack bushing.





8. Apply the specified oil to the entire surface of the O-ring and install it in the rack bushing.
9. Apply the specified grease to the rack teeth and wrap with vinyl tape.
Recommended grease: Multipurpose grease SAE J310, NLGI No.2





NOTE: Do not plug the vent hole in the rack with grease.





10. Wrap the rack end with vinyl tape, apply a coating of the specified fluid, and then install the rack bushing and rack stopper.

NOTE: Do not allow oil seal retainer spring to slip out.





11. Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing. Install the circlip while fuming the rack stopper.

NOTE: The circlip end should not be visible through the notched hole of the rack housing.





12. Using special tool, install the oil seal and the ball bearing in the valve body.





13. When installing seal rings, press firmly into valve groove. Apply specified fluid.





14. Apply the specified oil and grease to the pinion valve assembly and install in the gear housing assembly.
Recommended fluid: PSF-3 type
Recommended grease: Multipurpose grease SAE J310, NLGI No.2





15. Apply the specified oil and then use the special tool to install the seal in the valve body housing.





16. Install the valve body assembly with the seal ring to the gear box.





17. Install the tab washer and the tie rod and stake the tab washer end at two points over the tie rod.

NOTE:
1. Align the tab washer pawls with the rack grooves.
2. Always use a new tab washer.





18. With the pinion turned all the way clockwise, tighten the self-locking nut.

CAUTION: Always use a new nut.





19. Apply semi drying sealant to the threaded section of the end plug and tighten to the specified torque.
Tightening torque: 50 - 70 Nm (500 - 700 kg-cm, 37 - 52 ft. lbs.)
20. Stake the end plug at two points on its circumference with a punch.





21. Install the bushing, rack support yoke, rack support spring and yoke plug in the order shown. Apply semidrying sealant to the threaded section of the yoke plug before installation.





22. With the rack placed in the center position, attach the yoke plug to the gear housing. Tighten the yoke plug to 15 Nm (150 kg-cm, 11 ft. lbs.), using the special tool. Loosen the yoke plug approximately 30 to 60°, and tighten the locking nut to the specified torque.
Tightening torque: 50 - 70 Nm (500 - 700 kg-cm, 37 - 52 ft. lbs.)





23. Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
24. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Recommended grease: Silicone grease
25. Install the attaching band to the bellows.

NOTE: When the bellows are installed, a new band must be used.

26. Install the bellows in position, taking care not to twist it.





27. Fill the dust cover inner side and lip with the specified multipurpose grease, and place the dust cover in position with the clip ring attached in the groove of the tie rod end.





28. Screw in tie rod end to have its right and left length as illustrated. Lock with lock nut.





29. Push in the power steering gear box assembly from the right side of the vehicle.
30. Install the dust cover mounting plate.
31. Connect the dust cover to its mounting plate with a new strap.





32. Connect the steering gear box assembly to the steering column and shaft assembly.

NOTE: This work should be done by two persons. While one is pushing the gear box assembly toward the steering column and shaft assembly from underside of the vehicle, the other one is connecting the gear box to the steering column and shaft.

33. Remaining installation procedure is the reverse order of removal.
34. After installation, bleed the system.