Dissembly, Inspection and Reassembly

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 looked, 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.

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





12. Remove the yoke plug locking nut.





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





14. Remove the rack support spring, 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 counter clockwise and remove the circlip.





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

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





19. Remove the 0-ring from the rack bushing.





20. Remove the oil seal from the rack bushing.





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





22. Use the Special Tool (09565-21000) to remove the oil seal and ball bearing from the valve body housing.





23. Remove the ball bearing from the gear housing.

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





24. Remove the needle bearing from the gear housing.





25. Use the Special Tools (09573-21200, 09555-21000) to remove the back washer and oil seal from the gear housing.

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

INSPECTION
RACK
1. Check for the rack tooth face damage or wear
2. Check for the oil seal contact surface damage
3. Check for the bending or twisting
4. Check for the oil seal ring damage or wear of





5. Check for the oil seal damage or wear

PINION VALVE
1. Check for the 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

BEARING
1. Check for the seizure or abnormal noise during bearing rotation
2. Check for the excessive play
3. Check for the missing needle bearings

OTHERS
1. Check for the damage of the gear housing cylinder bore
2. Boot damage, cracking or aging

ASSEMBLY
1. Apply the specified oil to the entire surface of the rack oil seal.

Recommended oil:
Power steering fluid 3 type





2. Install back-up 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 (09432-21600) and install it into the gear housing (until the special tool contacts the gear housing).

CAUTION: Note the direction of the needle bearing.

5. Apply the specified grease to the ball bearing and install using the Special Tool (09222-21100).

NOTE: Always use a new bearing.

Recommended grease Multipurpose grease SAE J310, NLGI No.2





6. Apply the specified oil to the entire surface of the rack bushing oil seal.
Recommended oil Power steering fluid 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

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





10. Insert the rack into the gear housing.
Then, install the rack bushing and rack stopper.





11. Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing.
Then, install the circlip while turning the rack stopper.

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





12. Using Special Tool (09432-21600), install the oil seal and the ball bearing in the valve body.





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





14. Apply the specified oil and then use the Special Tool (09434-14200) to install the seal in the valve body housing.





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





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

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





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





19. Stake the end plug at two points on its circumference with a punch.





20. Install the bushing, rack support, rack support spring and rack support cover in the order shown. Apply semi-drying sealant to the threaded section of the rack support cover before installation.
21. With the rack placed in the center position, attach the rack support cover to the gear housing. Tighten the rack support cover within the range of 20 - 25 Nm (200 - 250, Kg-cm, 14.5 - 18 ft. lbs.), using the Special Tool (09565-21100). Loosen the rack support cover approximately 10°, and tighten the locking nut to the specified torque.





22. Tighten the feed tube to the specified torque and in stall the mounting rubber using adhesive.
Tightening torque 50 - 70 Nm (500 - 700 kg-cm, 37 - 52 ft. lbs.)
23. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
24. Install the attaching band to the bellows.

CAUTION: When the bellows are installed, new bands must be used.





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





26. 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.
27. Install the tie rods so that the length of the left and right tie rods are equal.
Standard value
Tie rod length: 185.2 ±1 mm (7.3 ±0.04 inch)





28. Confirm the pinion preload.