Repair Procedures
Removal
1. Drain the power steering fluid by disconnecting the return hose (A).
2. Disconnect the pressure tube (B) from the power steering oil pump (A) by loosening eye bolt.
Tightening torque :
55 - 65N.m (5.5 - 6.5kgf.m, 40 - 47lb-ft)
3. Remove the bolt (A) connecting steering gear to universal joint.
Tightening torque :
13 - 18N.m (1.3 - 1.8kgf.m, 9.4 - 13.0lb-ft)
CAUTION:
Keep the neutral-range to prevent the damage of the clock spring inner cable when you handle the steering wheel.
4. Remove the both front wheel & tire assemblies.
5. Loosen the Driveshaft castle nut, and then remove the tie rod end (A) from the knuckle (B) by using a SST 09568-4A000.
Tightening torque :
24 - 34N.m (2.4 - 3.4kgf.m, 17 - 26lb-ft)
6. Remove lower arm ball joint assembly bolts (A).
Tightening torque :
100 - 120N.m (10 - 12kgf.m, 72 - 86lb-ft)
7. Disconnect the stabilizer link (B) from the strut assembly (A).
Tightening torque :
35 - 45N.m (3.5 - 4.5kgf.m, 25 - 33lb-ft)
8. Repeat on the other side.
9. Remove the dust cover by loosening the bolts (A).
10. Loosen the bolts (A), and then remove the heat protector.
11. Remove the muffler mounting rubber (A).
12. Remove the front and rear roll stopper bolt (A, B).
Tightening torque :
50 - 65N.m (5.0 - 6.5kgf.m, 36 - 47lb-ft)
13. Remove the sub-frame by loosening the bolts and nuts (A).
Tightening torque :
95 - 120N.m (9.5 - 12.0kgf.m, 69 - 87lb-ft)
14. Remove the rear roll stopper by loosening the bolt.
Tightening torque :
50 - 60N.m (5.0 - 6.0kgf.m, 36 - 43lb-ft)
15. Disconnect the pressure hose and return tube & hose assembly from the valve body housing.
16. Remove the power steering gear box (A) by loosening the mounting bolt (B).
Tightening torque :
60 - 80N.m (6.0 - 8.0kgf.m, 43 - 58lb-ft)
Disassembly
1. Remove the tie rod end (B) from the tie rod (A).
2. Remove the bellows band (A).
3. Remove the bellows clip (A).
4. Pull the bellows out toward the tie rod.
NOTE:
Check for rust on the rack when the bellows are replaced.
5. Remove the feed tube (A) from the rack housing.
6. While moving the rack slowly, drain the fluid from the rack housing.
7. Remove the tie rod (B) from the rack (A).
CAUTION:
Remove the tie rod (B) from the rack (A), taking care not to twist the rack.
8. Remove the yoke plug locking nut (A).
9. Remove the yoke plug (A) with a 14 mm socket.
10. Remove the lock nut (D), yoke plug (C), rack support spring (B)and rack support yoke (A) from the gear box.
11. When the end of the circlip comes out of the notched hole (B) of the housing rack cylinder (C), turn the rack stopper (A) clockwise and remove the circlip.
CAUTION:
Be careful not to damage the rack.
12. Remove the rack bushing and rack from the rack housing.
13. Remove the O-ring (A) from the rack bushing (B).
14. Remove the oil seal (B) from the rack bushing (A).
15. Remove the valve body from the valve body housing with a soft hammer.
16. Using the special tool, remove the oil seal and ball bearing from the valve body housing.
17. Remove the oil seal and O-ring from the rack housing.
CAUTION:
Be careful not to damage the pinion valve cylinder inside of the rack housing.
18. Using the special tool (09573-21200, 09555-21000), remove the oil seal (A) from the rack housing.
CAUTION:
Be careful not to damage the rack cylinder inside of the rack housing.
Inspection
1. Rack
(1) Check for rack tooth face damage or wear
(2) Check for oil seal contact surface damage
(3) Check for rack bending or twisting
(4) Check for oil seal ring damage or wear
(5) Check for oil seal damage or wear
Vent hole
2. Pinion valve
(1) Check for pinion gear tooth face damage or wear
(2) Check for oil seal contact surface damage
(3) Check for seal ring damage or wear
(4) Check for oil seal damage or wear
3. Bearing
(1) Check for seizure or abnormal noise during a bearing rotation
(2) Check for excessive play
(3) Check for missing needle bearing rollers
4. Others
(1) Check for damage of the rack housing cylinder bore
(2) Check for boot damage, cracking or aging
Reassembly
1. Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid :PSF-III
2. Install the backup washer and oil seal (A) to the specified position in the rack housing.
3. Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid :PSF-III
4. Install the oil seal (A) in the rack bushing (B).
5. Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
6. Apply the specified grease to the rack teeth.
Recommended grease :
Multipurpose grease SAE J310a NLGI No.2
NOTE:
Do not plug the vent hole (A) in the rack with grease.
7. Insert the rack (A) into the rack housing (B) and install the rack bushing (C).
8. Using a special tool, install the oil seal and the ball bearing in the valve body housing.
9. After applying the specified fluid and grease to the pinion valve assembly (A), install it in the rack housing assembly.
10. Install the rack support yoke (A), rack support spring (B), yoke plug (C) and lock nut (D) in the order shown in the illustration. Apply semi-drying sealant to the threaded section of the yoke plug before installation.
11. Install the locking nut with a specified torque, after adjusting the rack support work as following instruction.
(1) Place the rack in the center position.
(2) Tighten the work plug with a specified torque.
Specified torque :
Manual 9 - 11N.m(0.9 - 1.1kgf.m,6.5 - 7.9lb-ft), Power 20(2,14.5)
(3) Reciprocate the rack slowly 5 times.
(4) Place the rack in the center position again, and then loosen the work plug.
(5) Tighten the work with a specified torque, and turn at a certain degree in reverse.
Specified torque :
Manual 4.5 - 6.5N.m(0.45 - 0.65kgf.m,3.25 - 4.70lb-ft),
Power 5 - 6N.m(0.5 - 0.6kgf.m,3.62 - 4.34lb-ft)
Reverse angle :
25 ± 5 (Manual), 35 (Power)
(6) Tighten the yoke lock nut without moving yoke plug.
Specified torque :
Manual 40 - 50N.m(4 - 5kgf.m,28.9 - 36.2lb-ft),
Power 50 - 60N.m(5 - 6kgf.m,36.2 - 43.4lb-ft)
12. Tighten the feed tube (A) to the specified torque and install the mounting rubber using adhesive.
Tightening torque :
25 - 30 N.m (2.5 - 3 kgf.m, 18.0 - 21.7 lb-ft)
13. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Recommended grease :Silicone grease
14. Install the new attaching band to the bellows.
NOTE:
When the bellows are installed, a new band must be used.
15. Install the bellows in position, taking care not to twist it.
16. Temporarily install the tie rod (A) to the tie rod end (B).
17. Check for total pinion preload.
Total pinion preload :
0.6 - 1.3 N.m (6 - 13 kgf.cm, 0.4 - 1.0 lb-ft)
Installation
NOTE:
Be sure to connect between a tube and a hose as shown in the illustration.
1. Installation is the reverse of removal.
2. After installation, bleed the power steering system.
3. Adjust the wheel alignment.