Disassembly and Assembly

Disassembly

1. Remove steering gear.
2. Remove two union bolts and four gaskets, then pressure tubes.
3. Clamp gear housing in vise, the place matchmarks on tie rod end and rack end and loosen locknut. Remove tie rod end and locknut.
4. Remove left hand rack boot, dust seal, then secure ball joint of rack end in vise and unstake claw washer. Avoid any impact to rack.

Fig. 15 Power Steering Rack Service:

5. Using service tool No. 09922-10010 or equivalent and a 22 mm spanner, remove rack end and claw washer as shown in Fig. 15.
6. Loosen two screws of rack end boot clamps, then secure damper end in a vise. Using a screwdriver and a hammer, unstake claw washer.

Fig. 16 Power Steering Rack Service:

7. Using service tool No. 09922-10010 or equivalent and a 22 mm spanner, remove rack end and claw washer as shown in Fig. 16. Remove rack end boot.
8. Remove rack bracket.

Fig. 17 Power Steering Rack Service:

9. Using service tool No. 09922-10010 or equivalent, remove rack guide spring cap locknut as shown in Fig. 17.
10. Using a 24 mm hexagon wrench, remove rack guide spring cap, then rack guide spring, rack guide and washer.
11. Remove grease cap. Wind vinyl tape on serrated part of control valve shaft to prevent damage to cap.
12. Remove control valve bolts, pull out control valve with housing, then remove O-ring from valve housing.
13. Using service tool No. 09631-22060 or equivalent, loosen bearing guide nut. Wind vinyl tape on serrated part of control valve shaft to prevent damage to oil seal lip.
14. Using a plastic hammer, tap out control valve. Ensure not to damage oil seal lip. Remove bearing guide nut and O-ring from bearing guide nut. Ensure not to damage oil seal lip.
15. Using service tool No. 09631-20090 or equivalent, remove cylinder end stopper and O-ring from stopper.
16. Lightly tap edge of rack housing with a hammer and remove spacer.
17. Using a brass bar, press out steering rack. Remove oil seal from steering rack.
18. Using service tool No. 09631-12020 or equivalent, press out oil seal and spacer.

Inspection

1. Using a dial indicator, check rack for runout and for teeth wear or damage. Maximum runout is .006 inch. Check back surface for wear or damage. If worn or damaged, replace it.
2. If necessary, replace control valve housing oil seal and bearing as follows:
a. Press oil seal and bearing out with 17 mm socket wrench.
b. Coat new seal with fresh power steering fluid, then press seal in with service tool No. 09608-30012 or equivalent.
c. Press in bearing with service tool No. 09608-30012 or equivalent.
3. If necessary, replace bearing guide nut oil seal as follows:
a. Remove oil seal with screwdriver.
b. Coat new seal with fresh power steering fluid.
c. Tap in new seal with service tool No. 09630-24013 or equivalent.
4. If necessary, replace pressure control valve as follows:
a. Remove three bolts with pressure control valve.
b. Remove three O-rings from control valve housing.
c. Coat new O-rings with fresh power steering fluid and install on control valve housing.
d. Install new pressure control valve with three bolts. Torque to 13 ft. lb.
5. If necessary, replace steering rack teflon ring and O-ring as follows:
a. Remove teflon ring and O-ring with screwdriver.
b. Coat new O-ring with fresh power steering fluid.
c. Expand new teflon ring with fingers. Ensure not to over-expand teflon ring. Install ring on steering rack.
d. Coat teflon ring with fresh power steering fluid and snug down with fingers.
6. If necessary, replace control valve teflon rings as follows:
a. Using a screwdriver, remove four teflon rings. Ensure not to damage control valve.
b. Install new teflon rings to service tool No. 09631-20070 or equivalent, and expand them.
c. Install new teflon rings to control valve.
d. Coat teflon rings with fresh power steering fluid and snug down with fingers. Ensure not to damage teflon rings.
e. Carefully slide tapered end of service tool over teflon rings to seat rings.
7. If necessary, replace hydraulic reaction chamber teflon rings and O-rings as follows:
a. Using a screwdriver, remove two teflon rings and two O-rings. Ensure not to damage control valve.
b. Coat new O-rings with fresh power steering fluid and install them.
c. Expand new teflon rings with fingers. Ensure not to over-expand teflon rings.
d. Install new teflon rings to control valve.
e. Coat new teflon rings with fresh power steering fluid and snug down with fingers. Ensure not to damage teflon rings.
f. Carefully slide tapered end of service tool No. 09631-32020 over teflon rings to seat rings.
8. If necessary, replace rack end as follows:
a. Place matchmarks on rack end, then secure rack end in a suitable vise.

Fig. 18 Power Steering Rack Service:

b. Using service tool No. 09922-10010 or equivalent, loosen damper bracket locknut as shown in Fig. 18. Use a left handed thread locknut.
c. Remove locknut and damper bracket.
d. Apply sealant (Loctite 242 or equivalent) to locknut threads.
e. Install steering damper bracket and temporarily tighten locknut.
f. Secure rack end in a suitable vise, then use service tool No. 09922-10010 or equivalent to torque locknut so matchmarks are aligned. Specification torque is 61 ft. lb., torque is 45 ft. lb. Use a torque wrench with a fulcrum length of 13.39 inch. Use a left handed thread locknut.
9. Inspect rack housing needle bearings for scratches. If scratches are present, replace needle bearing(s).
10. Inspect cylinder end stopper bushing for scratches. If scratches are present, replace cylinder end stopper, then coat with fresh power steering fluid.

Assembly

1. Coat all sliding components with fresh power steering fluid or molybdenum disulphide lithium base grease.
2. Coat new oil seal lip with fresh power steering fluid and insert service tool No. 09631-12020 into oil seal and spacer. Softly tap in spacer and oil seal.
3. Install service tool No. 09631-20051 to rack (if necessary, scrape burrs off rack teeth end and burnish). Coat service tool with fresh power steering fluid and insert rack into cylinder, then remove service tool.
4. Install cylinder end stopper, oil seal and spacer as follows:
a. To prevent damage to oil seal lip, wind vinyl tape on steering rack end and coat with fresh power steering fluid.

Fig. 19 Power Steering Rack Service:

b. Install oil seal by pushing it into cylinder, without tilting, in direction shown in Fig. 19.
c. Using service tool No. 09620-30010 or equivalent, drive in spacer.
d. Using service tool No. 09620-30010 or equivalent, drive in cylinder end stopper until it is tightly installed.
e. Using service tool No. 09631-20090 or equivalent, tighten cylinder end stopper.
5. Check air tightness as follows:
a. Install service tool No. 09631-22030 or equivalent to unions of rack housing.
b. Using a vacuum pump, apply 15.75 inch Hg. of vacuum for about 30 seconds.
c. Ensure of no change in vacuum. If there is change in vacuum, check installation of rack housing oil seals.
6. Install control valve as follows:
a. To prevent damage to oil seal lip, wind vinyl tape on control valve shaft.
b. Coat teflon rings with fresh power steering fluid.
c. Install control valve into control valve housing. If necessary, scrape burrs off bearing guide nut threads by stake.
d. Coat new O-rings with fresh power steering fluid and install to bearing guide nut.
e. Using service tool No. 09631-22060 or equivalent, torque bearing guide nut. Specification torque is 24 ft. lb., torque is 20 ft. lb. Use a torque wrench with a fulcrum length of 11.81 inch.
f. Using a chisel, stake bearing guide nut and valve housing.
7. Coat new O-ring with fresh power steering fluid and install to valve housing.
8. Install control valve housing with two bolts and torque to 13 ft. lb.
9. Install rack guide, washer and rack guide spring.
10. Apply sealant (Loctite 242 or equivalent) to two or three threads of spring cap, then install and torque spring cap with a 24 mm wrench to 18 ft. lb.
11. Adjust preload as follows:
a. Using a 24 mm wrench, return spring cap 12°.
b. Using service tool No. 09616-00010 or equivalent, turn control valve shaft right and left one or two times.
c. Loosen spring cap until rack guide spring is not functioning.
d. Using service tool No. 09616-00010 or equivalent, a small torque wrench and a 24 mm wrench, tighten rack guide spring cap until preload is within specifications. Turning preload is 8.7-17.3 in. lb.
12. Apply sealant (Loctite 242 or equivalent) to two or three threads of spring cap locknut, then using service tool No. 09922-10010 or equivalent, install and torque locknut with a 24 mm wrench. Specification torque is 50 ft. lb., torque is 37 ft. lb. Use a torque wrench with a fulcrum length of 13.39 inch.
13. Recheck preload. Turning preload should be 0.0-17.3 in. lb.
14. Install left hand rack end as follows:
a. Install new claw washer. Align claws of claw washer with rack grooves.

Fig. 20 Power Steering Rack Service:

b. Using service tool No. 09922-10010 or equivalent and 22 mm spanner, install and torque rack end as shown in Fig. 20. Specification torque is 86 ft. lb., torque is 64 ft. lb. Use a torque wrench with a fulcrum length of 14.96 inch.
c. Using a brass bar and a hammer, stake claw washer. Avoid any impact to rack.
15. Install rack bracket bolt from below and temporarily tighten nut. Fully tighten nut after installing steering gear assembly.
16. Install right hand rack boot and rack end as follows:
a. Temporarily install rack boot and two clamps. Smaller rack diameter goes on rack housing side, larger rack diameter goes on rack end side.
b. Install new claw washer. Align claws of claw washer with rack grooves.

Fig. 21 Power Steering Rack Service:

c. Using service tool No. 09922-10010 or equivalent and 22 mm spanner, install and torque rack end as shown in Fig. 21. Specification torque is 86 ft. lb., torque is 64 ft. lb. Use a torque wrench with a fulcrum length of 14.96 inch.
d. Remove service tool and temporarily install steering damper.

Fig. 22 Power Steering Rack Service:

e. Check that installation hole of turn pressure tube and steering damper are positioned as how in Fig. 22. Dimension is .61-.69 inch.
f. Remove steering damper. If steering damper bracket is positioned incorrectly, use service tool to loosen locknut, then adjust position of steering damper and torque locknut again. Specification torque is 61 ft. lb., torque is 45 ft. lb. Use a torque wrench with a fulcrum length of 13.39 inch. Use a left handed thread locknut.
g. Secure steering damper bracket in a suitable vise.
h. Using a brass bar and a hammer, stake claw washer.

Fig. 23 Power Steering Rack Service:

i. Place rack boot clamp as shown in Fig. 23, and tighten screws until dimension is within .08-.20 inch.
17. Install left hand rack boot as follows:
a. Ensure tube hole is not clogged with grease. If tube is clogged, pressure will change after assembly and when steering wheel is turned.

Fig. 24 Power Steering Rack Service:

b. Install rack boot and clamp. Place rack boot clamp as shown in Fig. 24, and tighten screws until dimension is with in .08-.20 inch.
c. Install clip.
d. Using service tool 09616-00010 or equivalent, turn control valve shaft right and left one or two times to check that rack boot moves smoothly.
18. Install rack end dust seal, then using a screwdriver, install set ring, then clip.
19. Screw locknuts and tie rod ends onto rack ends until matchmarks are aligned. After adjusting toe-in, torque locknuts.
20. Install turn pressure tubes as follows:
a. Install two new union seats.
b. Using service tool No. 09633-00020 or equivalent, install two tubes (control valve housing side). Specification torque is 18 ft. lb., torque is 14 ft. lb. Use a torque wrench with a fulcrum length of 9.84 inch.
c. Install two union bolts over four new gaskets and torque to 22 ft. lb.