Steering Gear: Service and Repair

REMOVAL
1. Place the front wheels facing straight ahead.
2. Remove the steering wheel pad.
3. Remove the steering wheel.
4. Disconnect the right and left hand tie rod ends.
5. Disconnect the sliding yoke.
6. Disconnect the pressure feed and the return tubes by doing the following.
a. Pressure feed tube: Remove the union bolt and gasket.





b. Return tube: Remove the union bolt and two gaskets.

7. Disconnect the two tube clamps after removing the bolt.
8. Remove the power steering gear assembly by doing the following.
a. Disconnect the connector.
b. Remove the two gear assembly set bolts and nuts.

DISASSEMBLY

NOTE: When using a vise, do not overtighten it.

1. Remove the two turn pressure tubes by doing these procedures.
a. Remove the union bolt and two gaskets.





b. Using the 09633 - 00020 SST, remove the tube.
c. Remove the two union seats from the control valve housing.





2. Using the 09612 - 00012 SST, secure the power steering gear assembly in a vise.





3. Remove the right and left hand tie rod ends and lock nuts after placing matchmarks on the tie rod end and rack end, and loosening the lock nut.
4. On the left side remove the clip, clamp and the rack boot.

NOTE: Be careful not to damage the boot.

5. Remove the dust seal by doing the following.
a. Remove the clip.





b. Using a screwdriver, remove the set ring.

NOTE: Be careful not to damage the dust seal.

6. Remove the left hand rack end and claw washer.





a. Using a screwdriver and a hammer, unstake the washer.

NOTE: Avoid any impact to the steering rack.





b. Using a (22 mm) spanner to hold the steering rack, and using the 09922 - 10010 SST, remove the rack end.

NOTE: Use the 09922 - 10010 SST in the direction shown in the illustration.

7. Remove the right hand rack end and the claw washer by doing the following.





a. Using a screwdriver and hammer, unstake the washer.

NOTE: Avoid any impact to the steering rack.





b. Using a (22 mm) spanner to hold the steering rack, and using the 09922 - 10010 SST, remove the rack end.

NOTE: Use the O9922 - 10010 SST in the direction shown in the illustration.

8. Remove the right hand rack boot and the two clamps.

NOTE: Be careful not to damage the boot.

9. Remove the rack housing No.2 bracket after first removing the bolt and nut.
10. Using the 09922 - 10010 SST, remove the rack guide spring cap lock nut.





NOTE: Use the 09922 - 10010 SST in the direction shown in the illustration.

11. Using a (24 mm) hexagon wrench , remove the rack guide spring cap.
12. Remove the rack guide spring, washer and the rack guide
13. Remove the dust cover.
14. Remove the control valve housing with the control valve assembly by doing the following.
a. Remove the two bolts.
b. Remove the O-ring from the housing.

15. Remove the control valve assembly by doing the following.





a. Using the 09631 - 22060 Special Service Tool (SST), loosen the bearing guide nut.
b. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.





c. Using a plastic hammer, tap out the valve assembly.
d. Remove the bearing guide nut.
e. Remove the O-ring from the bearing guide nut.





16. Using the 09631 - 20090 SST, remove the cylinder end stopper and spacer.
17. Remove the steering rack and the oil seal, doing the following.





a. Using a brass bar and a press, press out the rack with the oil seal.

NOTE: Take care to not drop the rack.

b. Remove the oil seal from the rack.





18. Using the 09950-60010(09951-00280) 09950-70010(09951-07200) SST, press out and remove the oil seal and spacer.

INSPECTION AND REPLACEMENT

NOTE: When using a vise, do not overtighten it.

1. Inspect the steering rack, doing the following.





a. Using a dial indicator, check the rack for runout, and for teeth wear or damage. The maximum runout should be 0.30 mm (0.0118 inch).
b. Check the back surface for wear or damage.

2. If necessary, replace the oil seal and bearing by following these procedures.





a. Using the 09950 - 60010 (09951 - 00250) 09950-70010 (09951 -07100) Special Service Tool (SST), press out the oil seal and bearing from the control valve housing.
b. Coat a new oil seal lip with power steering fluid.





c. Using the 09950 - 60010 (09951 - 00180, 09951 - 00320, 09952 -06010), 09950-70010 (09951-07200) SST, press in the oil seal.

NOTE: Make sure to install the oil seal facing the correct direction.

d. Coat a new bearing with molybdenum disulfide lithium base grease.





e. Using the SST 09950 - 60010 (09951 - 00350) 09950-70010 (09951 - 07200) SST, press in the bearing.

3. If necessary, replace the oil seal, doing the following.





a. Using the 09950 - 60010 (09951 - 00350) 09950-70010 (09951 -07100) SST and a hammer, tap out the oil seal from the bearing guide nut. b. Coat a new oil seal lip with power steering fluid.





c. Using the 09950 - 60010 (09951 - 00290, 09951 - 00420, 09952 - 06010) SST, press in the oil seal.

NOTE: Make sure to install the oil seal facing the correct direction.

4. If necessary, replace the pressure control valve assembly, doing these steps.
a. Remove the three bolts.





b. Remove the three O-rings from the control valve housing.
c. Coat the three new O-rings with power steering fluid and install them on the valve housing.
d. Install a new valve assembly with the three bolts, tightening the bolts to 18 Nm (13 ft. lbs.).

5. If necessary, replace the teflon ring and the O-ring, doing the following.





a. Using a screwdriver, remove the teflon ring and O-ring from the steering rack.

NOTE: Be careful not to damage the groove for the teflon ring.

b. Coat a new O-ring with power steering fluid and install it.





c. Expand a new teflon ring with your fingers.

NOTE: Be careful not to overexpand the ring.

d. Coat the ring with power steering fluid.





e. Install the ring to the rack, and snug it down with your fingers.

6. If necessary, replace the teflon rings by doing these procedures.





a. Using a screwdriver, remove the four rings from the control valve assembly.

NOTE: Be careful not to damage the grooves for the ring.

b. Expand four new rings with your fingers.

NOTE: Be careful not to overexpand the ring.

c. Coat the rings with power steering fluid.
d. Install the rings to the valve assembly, and snug them down with your fingers.





e. Carefully slide the tapered end of the 09631 - 20081 SST over the rings to seat them.

NOTE: Be careful not to damage the rings.

7. If necessary, replace the teflon rings and the O-rings, doing the following.





a. Using a screwdriver, remove the two teflon rings and O-rings from the control valve assembly.

NOTE: Be careful not to damage the grooves for the ring.

b. Coat two new O-rings with power steering fluid and install them to the valve assembly.
c. Expand two new teflon rings with your fingers.

NOTE: Be careful not to overexpand the rings.

d. Coat the rings with power steering fluid.





e. Install the rings to the valve assembly, and snug them down with your fingers.
f. Carefully slide the tapered end of the 09631 - 32020 SST over the ring to seat them.

NOTE: Be careful not to damage the rings.

8. If necessary, replace the right hand rack end by doing these steps.





a. Place matchmarks on the steering damper bracket lock nut and steering damper bracket.





b. Using the 09922 - 10010 SST, loosen the nut.

NOTE:
^ Use the 09922 - 10010 SST in the direction shown in the illustration.

^ Use a left handed thread nut.

c. Apply part No.08833 - 00080.THREE BOND 1344. LOCTITE 242 or equivalent sealant to the nut threads.
d. Install the bracket and temporarily tighten the nut.
e. Use the 09922 - 10010 SST to tighten the nut to 62 Nm (45 ft. lbs.) so that the matchmarks become aligned.

NOTE:





^ Use the 09922 - 10010 SST in the direction shown in the illustration.

^ Use a left handed thread lock nut.

^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

9. Inspect the bearing by doing the following.





a. Check the needle roller bearing for pitmarks or damage. If faulty, replace the rack housing.
b. Coat the inside of the bearing with molybdenum disulfide lithium base grease.

10. If necessary, replace the rack end guide, doing the following.
a. Using a screwdriver, remove the rack end guide from the cylinder end stopper.
b. Coat a new rack end guide with molybdenum disulfide lithium base grease.





c. Install the rack end guide into the cylinder end stopper.

ASSEMBLY

NOTE: When using a vise, do not overtighten it.

1. Coat the assembly with power steering fluid or molybdenum disulfide lithium base grease.
2. Install the oil seal and spacer, doing these steps.
a. Coat a new oil seal lip with power steering fluid.





b. Using the 09950 - 60010 (09951 - 00260, 09951 - 00430, 09951 - 06010), 09950-70010 (09951 -07360) Special Service Tool (SST) and a press, press in the oil seal and spacer.

NOTE:
^ Make sure to install the oil seal facing the correct direction.

^ Take care that the oil seal does not get reversed as you install it.

3. Install the steering rack, doing the following.
a. Install the 09631 - 20102 SST to the rack.





NOTE: If necessary, scrape the burrs off the rack teeth end and burnish.

b. Coat the SST with power steering fluid.
c. Install the rack into the rack housing.
d. Remove the SST.

4. Install the oil seal by doing these steps.





a. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
b. Coat a new oil seal lip with power steering fluid.
c. Install the oil seal by pushing it into the rack housing without tilting.

NOTE: Make sure to install the oil seal facing the correct direction.

5. Install the spacer and cylinder end stopper by doing the following.





a. Using the 09950 - 60010 09951 - 00260, 09951 - 00430 09952-06010), 09950-70010 (09951-07200) SST and a hammer, drive in the spacer.





b. Using the 09950 - 60010 (09951 - 00260, 09951 - 00440, 09952 - 06010), 09950-70010 (09951-07200) SST and a hammer, drive in the stopper until it is tightly installed.





c. Using the 09631 - 20090 SST, tighten the stopper to 59 Nm (43 ft. lbs.).

6. Perform an air tightness test by doing the following.





a. Install the 09631 - 22030 SST to the rack housing.
b. Apply 53.3 kPa (15.75 inch Hg) of vacuum for about 30 seconds.
c. Check that there is no change in the vacuum. If there is a change in the vacuum, check the installation of the oil seals.

7. Install the control valve assembly by doing the following.





a. Coat the teflon rings with power steering fluid.
b. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
c. Install the valve assembly into the control valve housing.

NOTE: Be careful not to damage the teflon rings and oil seal lip.

d. If necessary, scrape the burrs off the bearing guide nut threads by stake.
e. Coat a new O-ring with power steering fluid and install it to the nut.
f. Wind vinyl tape to the control valve shaft.





g. Using the 09631 - 22060 SST, tighten the nut to 28 Nm (20 ft. lbs.).

NOTE: Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).





h. Using a chisel, stake the nut and housing.

8. Install the control valve housing with the control valve assembly by doing the following.
a. Coat a new O-ring with power steering fluid and install it to the housing.
b. Install the valve housing with the valve assembly to the rack housing.
c. Tighten the two bolts to 18 Nm (13 ft. lbs.).

9. Install the rack guide, washer, rack guide spring and the rack guide spring cap, doing these procedures.
a. Apply part No. 08833 - 00080. THREE BOND 1344, LOCTITE 242 or equivalent sealant to two or three threads of the cap.
b. Temporarily install the cap.

10. Adjust the total preload by doing the following.
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the right and left hand rack ends.





b. Using a (24 mm) hexagon wrench, tighten the rack guide spring cap to 25 Nm (18 ft. lbs.).
c. Using a (24 mm) hexagon wrench, return the cap 12°.





d. Using the 09616 - 00010 SST, turn the control valve shaft right and left one or two times.
e. Using a (24 mm) hexagon wrench , loosen the cap until the rack guide spring is not functioning.





f. Using the 09616-00010 SST, a torque wrench and a (24 mm) hexagon wrench, tighten the cap until the preload is within the specification. The preload (turning) should be 1.0 - 1.9 Nm (8.7 - 17.3 inch lbs.).

11. Install the rack guide spring cap lock nut by doing these steps.
a. Apply part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent sealant to two or three threads of the nut.





b. Using a (24 mm) hexagon wrench to stop the rack guide spring cap rotating, and using the 09922 - 10010 SST, tighten the nut to 50 Nm (37 ft. lbs.).

NOTE:
^ Use the 09922 - 10010 SST in the direction shown in the illustration.

^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

c. Recheck the total preload. The (Preload turning) should be 1.0 - 1.9 Nm (0.0 - 17.3 inch lbs.).
d. Remove the right and left hand rack ends.

12. Install the dust cover.
13. Install the left hand rack end and the claw washer, doing the following.
a. Install a new washer and temporarily install the rack end.

NOTE: Align the claws of the washer with the steering rack grooves.





b. Using a (22 mm) spanner to hold the steering rack steady, and using the 09922 - 10010 SST, tighten the rack end to 88 Nm (65 ft. lbs.).

NOTE:
^ Use the 09922 - 10010 SST in the direction shown in the illustration.

^ Use a torque wrench with a fulcrum length of 380 mm (14.96 inch).





c. Using a brass bar and a hammer, stake the washer.

NOTE: Avoid any impact to the rack.


14. Install the rack housing No.2 bracket by installing the bolt from below and temporarily tighten the nut.

NOTE: Fully tighten the nut after installing the steering gear assembly.

15. Install the right hand rack boot, two clamps , claw washer and right hand rack end.





a. Temporarily install the rack boot and two new clamps.

NOTE: For the rack housing side, use the smaller boot. For the rack end side, use the larger boot.

b. Install a new claw washer.

NOTE: Align the claws of the washer with the steering rack grooves.





c. Using a (22 mm) spanner to stop the steering rack steady, and using the 09922 - 10010 SST, tighten the rack end to 88 Nm (65 ft. lbs.).

NOTE:
^ Use the 09922 - 10010 SST in the direction shown in the illustration.

^ Use a torque wrench with a fulcrum length of 380 mm (14.96 inch).





d. Using a brass bar and a hammer, stake the washer.

NOTE: Avoid any impact to the rack.





e. Place the clamp as shown, and tighten the screws until the dimension is within the specification. The dimension should be 2 - 5 mm (0.08 - 0.20 inch).

16. Install the left hand rack boot, clamp and clip.





a. Make sure that the tube hole is not clogged with grease.

NOTE: If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel turned.





b. Place a new clamp as shown, and tighten the screws until the dimension is within the specification of 2 - 5 mm (0.08 - 0.20 inch).

17. Install the dust seal, doing the following.
a. Using a screwdriver, install a new set ring.

NOTE: Be careful not to damage the seal.

b. Install the clip.

18. Install the right and left hand tie rod ends and the lock nuts by following these procedures.
a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
b. After adjusting the toe-in, tighten the lock nut to 56 Nm (41 ft. lbs.).
19. Install the two turn pressure tubes, doing the following.
a. Install 2 new union seats to the control valve housing.





b. Using the 09633 - 00020 SST, install the tube. Tighten the tube to 20 Nm (15 ft. lbs.).

NOTE:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).

^ This torque value is effective in case that SST is parallel to a torque wrench.

c. Tighten the union bolt to 29 Nm (22 ft. lbs.) over the two new gaskets.

INSTALLATION
1. Install the power steering gear assembly, doing the following.





a. Tighten the two gear assembly set bolts and nuts to 98 Nm (72 ft. lbs.).
b. Connect the connector.

2. Connect the two tube clamps and tighten the bolt to 17 Nm (12 ft. lbs.).
3. Connect the sliding yoke.
4. Connect the pressure feed and the return tubes as follows.
a. For the pressure feed tube: Tighten the union bolt over a new gaskets.
b. For the return tube: Tighten the union bolt to 49 Nm (36 ft. lbs.). with a new gasket on each side of the tube.

5. Connect the right and left hand tie rod ends.
6. Position the front wheels facing straight ahead.

NOTE: Do it with the front of the vehicle jacked up.

7. Install the center spiral cable.
8. Install the steering wheel by doing the following.
a. Align the matchmarks on the wheel and steering column main shaft.
b. Temporarily tighten the wheel set nut.
c. Connect the connector.

9. Bleed the power steering system.
10. Check the steering wheel center point.
11. Tighten the steering wheel set nut to 35 Nm (26 ft. lbs.).
12. Install the steering wheel pad.
13. Check the front wheel alignment.