Manual Steering Gear

DISASSEMBLY
Before disassembly, measure the rack starting force and pinion starting torque in the neutral (straight ahead) position for reference at reassembly.
1. Clean the rack and pinion assembly and mount it in a soft-jawed vise.

CAUTION: When mounting the rack In the vise, wrap a cloth around the rack and be careful not to damage It when tightening the vise.

2. Remove the tie rod assembly.





3. Remove the lock nut from the yoke plug.





4. Using Special Tool (09565-21100), remove the yoke plug.





5. Remove the yoke spring, cushion rubber and support yoke from the gear box.
6. Remove the dust cap.





7. Remove the oil seal from the gear box.





8. Remove the snap ring from the gear box. Remove the pinion together with the bearing.





9. Remove the bearing retainer snap ring from the pinion.





10. Using Special Tool (09565-21000), remove the bearing from the pinion.
11. Remove the bellows.





12. Using a chisel, unstake the right side rack end nut.





13. Move the rack all the way towards the rack housing and hold the toothed portion of the rack in a soft-jawed vise. Loosen the tie rod end and remove the tie rod assembly from the rack.





14. Remove the rack from the gear housing after removing pinion gear.

CAUTION: To prevent damage to the busing with the rack teeth, remove the rack from the left side.





INSPECTION

ASSEMBLY
1. Prior to reassembly, clean all gearbox components in a suitable solvent.





2. Press fit the bearing to the pinion with Special Tool (09432-22000).





3. Install the snap ring on the pinion.
4. Apply grease to the rack, pinion, bushing, needle roller bearing and other moving surfaces.

CAUTION: Do not seal the air passage In the housing bushing with grease.

Recommended grease Multipurpose grease SAE J310a, NLGI grade No.2 EP





5. After inserting the rack into the gear housing, install the pinion gear in mesh with the rack.

CAUTION:
1. Make sure that the rack is inserted into the gear housing from the left side.
2. Wipe off excessive grease.





6. Select and install the appropriate type of snap ring to minimize the play in the axial direction of the pinion.





7. Apply grease to the lip of the oil seal before installing the it in the gear box.

NOTE: Be sure to use a new oil seal.





8. Install the support yoke, cushion rubber, spring and yoke plug to the pinion gear box.

CAUTION: Apply grease to the cupped portion of the support yoke.





9. Adjust the yoke plug with Special Tool (09565-21000).
Tighten the yoke plug to 11 Nm (112 kg-cm, 8 ft. lbs.) and then back off 30° - 60°. Secure the yoke plug with the lock nut.

CAUTION:
1. Adjust the yoke plug with the rack in the neutral position.
2. Apply a sealer between the lock nut and the housing.

Tightening torque
Yoke plug lock nut 50 - 70 Nm (500 - 700 kg-cm, 37 - 52 ft. lbs.)
10. Install the tie rod end and bellows. Use and stake a new locking plate at each end.
11. The combined preload of the pinion (with bellows and grease) should be measured by turning the pinion at a rate of one revolution every 4-6 seconds with Special Tool (09565-11100). The rack starting force should also be measured.

CAUTION: The pinion preload should be measured over the full stroke of the rack.

Total pinion preload
±180° or less from neutral: 0.4 - 1.1 Nm (4 - 11 kg-cm, 3.5 - 9.5 inch lbs.)
±180° or more from neutral: 0.3 - 1.6 Nm (3 - 16 kg-cm, 2.4 - 14 inch lbs.)
Rack starting force : 50 - 300 N (5 - 30 kg, 11 - 66 lbs.)





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12. If the measured values are out of specification, replace the cushion rubber and yoke spring and readjust in accordance with step 9.