Repair Procedures

Replacement

1. Remove the front wheel & tire.

Tightening torque Nm (kgf.m, lb-ft):
90 - 110 (9.0 - 11.0, 65 - 80)

2. Disconnect the stabilizer link with the front strut assembly after loosening the nut.

Tightening torque Nm (kgf.m, lb-ft):
100 - 120 (10.0 - 12.0, 72 - 87)




3. Disconnect the tie-rod end with the knuckle using a SST (09568-2J100). After removing split pin and nut.




4. Loosen the bolt and then disconnect the universal joint assembly from the pinion of the steering gear box.

Tightening torque Nm (kgf.m, lb-ft):
30 - 35 (3.0 - 3.5, 22 - 25)





CAUTION:
Keep the neutral-range to prevent the damage of the clock spring inner cable when you handle the steering wheel.

5. Remove the cross member from the body by loosening the mounting bolts and nuts.












6. Remove steering gearbox from the cross member by loosening the bracket mounting bolts.
7. Installation is the reverse of the removal.

Disassembly

1. Remove the tie rod end (B) from the tie rod (A).




2. After mounting the tie rod end (A) in a vise, remove the dust cover (B) from the ball joint.




3. Remove the bellows band (A).




4. Remove the bellows clip (A).




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 (A) from the rack housing.




7. While moving the rack slowly, drain the fluid from the rack housing.
8. Unstake the tab washer (A) which fixes the tie rod (B) and rack (C) with a chisel.




9. 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.




10. Remove the yoke plug locking nut (A).




11. Remove the yoke plug (B) with a 14mm socket (A).




12. Remove the lock nut(D), yoke plug (C), rack support spring (B) and rack support yoke (A) from the gear box.




13. When the end of the circlip comes out of the notched hole of the housing rack cylinder, turn the rack stopper counterclockwise and remove the circlip.

CAUTION:
Be careful not to damage the rack.




14. Remove the rack bushing and rack from the rack housing.
15. Remove the O-ring (A) from the rack bushing (B).




16. Remove the oil seal (B) from the rack bushing (A).




17. Remove the valve body from the valve body housing with a soft hammer.
18. Using the special tool, remove the oil seal and ball bearing from the valve body housing.
19. 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.

20. 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




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