Disassembly 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 tubes from the gear housing.
7. While moving the rack slowly, drain the fluid from the gear housing.





8. Unstake the tab washer that fixes the tie rod and rack with a chisel.





9. Remove the tie rod from the rack.

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





10. Remove the rack support plug lock nut.





11. Using the special tool (09565-31300), remove the rack support plug.





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





13. Remove the end plug self-locking nut.
14. Detach the dust seal.
15. Remove the snap ring with a snap ring plier.





16. Remove the pinion and valve assembly together with the oil seal (upper) using a soft hammer.





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





18. 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.

CAUTION: Do not damage the rack.





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

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





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





21. Remove the oil seal from the rack bushing.





22. Drive out the ball bearing using special tool (09517-21400) and hammer.

CAUTION; Do not damage the pinion valve cylinder inside of the gear housing.





23. Drive out the needle bearing and oil seal.





24. Use the special tools (09555-21000, 09573-33100) to remove the back washer and oil seal from the gear housing.

CAUTION: Do not 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) Bending or twisting
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 rollers
4. Others
1) Damage of the gear housing cylinder bore
2) Boot damage, cracking or aging

ASSEMBLY
1. Apply the specified fluid to the entire surface of the oil seal and gear housing.
Recommended fluid Power steering fluid (PSF-3)





2. Using the special tools (09555-21000, 09573-21000, 09573 33000,09573-33100), 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 J310a, NLGI No.2





4. Install the needle bearing in the gear housing using special tool (09222-21100).





5. Set the scribed side of the oil seal (inner) in the special tool (09431-11000) and install in the gear housing.

CAUTION:
1) Note the direction of the oil seal.
2) Use a new oil seal.

6. Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid Power steering fluid (PSF-3)
7. Install the oil seal on the rack bushing.





8. Apply the specified fluid to the entire surface of the O-ring and install to the rack bushing using the special tool (09431-11000).





9. Apply the specified grease to the rack teeth and wrap with vinyl tape.
Recommended grease Multipurpose grease SAE J310a, NLGI grade #2 EP

CAUTION: Do not plug the vent hole in the rack with grease.
All cautions must clearly state the possible harmful result or risk. What would happen if the vent hole was plugged with grease?





10. Insert the rack into the gear housing.
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 and then install the circlip while turning the rack stopper.

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





12. Apply the specified fluid and grease to the pinion valve assembly and install to the gear housing assembly.
Recommended fluid Power steering fluid (PSF-3)
Recommended grease Multipurpose grease SAE J310a, NLGI Grade #2 EP





13. Install the ball bearing using special tool (09222-21100).
14. Install the pinion and valve assembly to the valve housing.





15. Install the oil seal using the special tool (09432-21601).
16. Install the snap ring with snap ring plier.





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

CAUTION: Always replace the self-locking nut with a new one.





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, 36 - 51 ft. lbs.)
19. Stake the end plug at two points on its circumference with a punch.





20. Install the tab washer and then the tie rod and peen the tab washer end at two points to the tie rod.

CAUTION:
1) Align the tab washer pawls with the rack grooves.
2) Use a new tab washer.





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





22. With the rack placed at the center position, attach the rack support plug to the gear housing. Tighten the rack support plug within the range of 20 - 25 Nm (200 - 250 kg cm, 14.5 - 18 ft. lbs.), using the special tool. Loosen the rack support plug for approximately 10° and adjust torque to the standard value.
Total pinion torque [Standard value] 0.6 - 1.3 Nm (6 - 13 kg cm, 0.4 - 0.9 ft. lbs.)
23. After adjusting, lock rack support plug with lock nut.

NOTE: When it cannot be adjusted within the specified return angle, check rack support plug components or replace.

24. Tighten the feed tube to the specified torque and install the mount rubber using adhesive.
25. Apply the specified grease to the bellows fitting position (fitting groove) of the tie rod.
Recommended grease Multipurpose grease SAE J310a, NLGI grade #2 EP
26. Install the new attaching band to the bellows.

CAUTION: Whenever the bellows are installed, a new band must be used.





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





28. Fill the dust cover inner side and lip with the specified multipurpose grease, and fix the dust cover in position with the clip ring attached in the groove of the tie rod end.
Recommended grease Multipurpose grease SAE J310a, NLGI grade #2 EP





29. Install the tie rods so that the length of the left and right tie rods will be equal to the standard value.
Tie rod free length [Standard value] 47.2 mm (1.86 inch)