Removal Overhaul and Installation

REMOVAL





1. Using the Special Tool, disconnect the tie rod end from the knuckle.
2. Disconnect the coupling bolt of universal joint assembly from the gear box.
3. Drain the fluid.





4. Disconnect the pressure and return hoses from the gear box.
5. Remove the gear box mounting bolts.
6. Remove the rear roll stopper and bracket.
7. Remove the stabilizer bar.
8. Pull the gear box out toward the right side of the vehicle.





CAUTION: When the gear box is to be removed, pull It out carefully and slowly so as not to cause damage to the boots.

INSPECTION AND ADJUSTMENT PRIOR TO DISASSEMBLY
Mount the gear box in a soft jawed vise.





CAUTION: Do not tighten the vise on the gear housing. Use the mounting section for 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.
Standard value
Total pinion preload 0.6 - 1.3 Nm (6 - 13 kg-cm, 5.2 - 11.3 inch lbs.)

CAUTION: 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 reach 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.
Standard value
Tie rod swing resistance (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 lbs.)[100 Nm (8.7 inch lbs.)], however 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.

INSTALLATION
1. Install with the projection on the mounting rubber of the gear housing aligned with the holes in the clamp and gear housing bracket.
2. Apply adhesive to the cylinder side mounting rubber so that its slitted part will not open.
3. Check that there are no oil leaks.
4. Confirm the steering wheel rotates smoothly.
5. Adjust the toe-in.





6. Install all parts with reference to the torque specification.