Disassembly and Assembly

Exploded View Of Steering Gear (Part 1 Of 2):

Exploded View Of Steering Gear (Part 2 Of 2):

DISASSEMBLY

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





1. Remove 2 turn pressure tubes.
a. Using Special Service Tool (SST) 09633-00020 or equivalent, remove the tube.
b. Remove the union seat from the rack housing.





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





3. Remove Right-Hand (RH) and Left-Hand (LH) tie rod ends and lock nuts.
Place matchmarks on the tie rod end and rack end.





4. Remove RH and LH clips, rack boots and clamps.
Using pliers, loosen the clamp, as shown in the illustration.

NOTICE:
- Be careful not to damage the boot.
- Mark the RH and LH boots.

5. Remove RH and LH rack ends and claw washers.





a. Using a screwdriver and hammer, stake back the washer.

NOTICE: Avoid any impact to the steering rack.





b. Using a spanner to hold the steering rack steady, and using SST 09922-10010, remove the rack end.

NOTICE:
- Use SST in the direction shown in the illustration.
- Mark the RH and LH rack ends.





6. Remove rack guide spring cap lock nut.
Using SST, remove the nut.

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

7. Remove rack guide spring cap.
8. Remove rack guide spring and rack guide sub-assembly.
9. Remove dust cover.





10. Remove control valve housing with control valve assembly.
a. Place matchmarks on the valve housing and rack housing.
b. Remove the 2 bolts.
c. Pull out the control valve assembly with the valve housing.
d. Remove the O-ring from the rack housing.
11. Remove control valve assembly.





a. Using SST 09631-20060, loosen the bearing guide nut.





b. Wind vinyl tape to the control valve shaft.
c. Using a plastic hammer, tap out the valve assembly with the nut from the control valve housing.

NOTICE: Be careful not to damage the oil seal lip.

d. Remove the nut from the valve assembly.

NOTICE: Be careful not to damage the oil seal lip.

e. Remove the O-ring from.the nut.





12. Remove cylinder end stopper and spacer.
a. Using SST 09631-20090, remove the stopper.
b. Remove the O-ring from the stopper.





13. Remove steering rack and oil seal.
a. Using SST 09950-70010 (09951-07200), press out the rack and oil seal.

NOTICE: Take care not to drop the rack.

b. Remove the oil seal from the rack.





14. Remove oil seal.
Using SST 09950-60010 (09951-00280), 09950-70010 (09951-07360), press out the oil seal.

INSPECTION





1. Inspect steering rack.
a. Using a dial indicator, check the rack for runout and for teeth wear and damage.
Maximum runout: 0.03 mm (0.0118 inch)
b. Check the back surface for wear and damage.
2. If necessary, replace oil seal and bearing.





a. Using SST 09950-60010 (09951-00260), 09950-70010 (09951-07150), 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 SST 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150), press in the oil seal.

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





d. Coat a new bearing with molybdenum disulfide lithium base grease.
e. Using SST 09950-60010 (09951-00330), 09950-70010 (09951-07150), press in the bearing.
3. If necessary, replace oil seal.





a. Using SST 09950-60010 (09951-00320), 09950-70010 (09951-07100), press out the oil seal from the bearing guide nut.





b. Coat a new oil seal lip with power steering fluid.
c. Using SST 09950-60010 (09951-00280, 09951-00360, 09952-06010), 09950-70010 (09951-07100), press in the oil seal.

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





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





5. Inspect bearing.
a. Check the bearing rotation condition and check for abnormal noise.
If the bearing is worn or damaged, replace the control valve assembly.
b. Coat the bearing with molybdenum disulfide lithium base grease.





6. Inspect bushing.
a. Check the inside of the bushing of the cylinder end stopper for cracks. If faulty, replace the bushing.
b. Apply molybdenum disulfide lithium base grease to the inside of the bushing.





7. If necessary, replace bushing.
a. Using a screwdriver, remove the bushing from the cylinder end stopper.

NOTICE: Be careful not to damage the cylinder end stopper.

b. Coat the inside of a new bushing with molybdenum disulfide lithium base grease.
c. Install the bushing.
8. If necessary, replace teflon ring and O-ring.





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

NOTICE: Be careful not to damage the groove for the ring.

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





c. Expand a new teflon ring with your fingers.

NOTICE: Be careful not to overexpand the ring.

d. Coat the ring with power steering fluid.





e. Install the ring to the rack, and settle it down with your fingers.
9. If necessary, replace teflon rings.





a. Using a screwdriver, remove the 4 rings from the control valve assembly.

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

b. Expand 4 new rings with your fingers.

NOTICE: Be careful not to overexpand the ring.

c. Coat the rings with power steering fluid.





d. Install the rings to the control valve assembly, and settle them down with your fingers.
e. Carefully slide the tapered end of SST 09631-20081 over the rings until the ring fits to the steering rack.

NOTICE: Be careful not to damage the rings.

REASSEMBLY

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

1. Coat with power steering fluid or molybdenum disulfide lithium base grease.





2. Install oil seal.
a. Coat a new oil seal lip with power steering fluid.
b. Using SST 09951-60010 (09951-0033O, 09951-00490, 09952-06010), 09950-70010 (09951-07360), press in the oil seal.
- 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 steering rack.
a. Install SST 09631-20102 to the rack.

HINT: If necessary, scrape the burrs oft.the rack teeth end and burnish.

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





4. Install oil seal.
a. Install SST 09631-20102 to the steering rack opposite end.
b. Coat SST with power steering fluid.
c. Coat a new oil seal lip with power steering fluid.
d. Install the oil seal by pushing it onto the SST without tilting.

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

e. Remove the SST.
5. Install spacer and cylinder end stopper.





a. Using SST 09950-60010 (09951-00280, 09951-00420, 09952-06010), 09950-70010 (09951-07200) and a hammer, drive in the spacer.
b. Coat a new O-ring with power steering fluid, and install it to the stopper.





c. Using a wooden block and hammer, drive in the stopper until it is tightly installed.

NOTICE: Be careful not to damage the O-ring.





d. Using SST 09631-20120, torque the stopper.
Torque: 59 Nm (43 ft. lbs.)





6. Air tightness test.
a. Install SST 09631-12071 to the unions of the rack housing.
b. Apply 53 kPa (15.75 inch Hg) of vacuum for about 30 seconds.
c. Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil seals.
7. Install control valve assembly.
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 control valve shaft.
c. Push the valve assembly into the control valve housing.

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

d. Coat a new O-ring with power steering fluid, and install the bearing guide nut.





e. Using SST 09631-20060, torque the nut.
Torque: 25 Nm (18 ft. lbs.)

NOTICE: Be careful not to damage the oil seal lip.





f. Using a punch, stake the nut.
8. Install control valve housing with control valve assembly.
a. Coat a new O-ring with power steering fluid, and install it to the valve housing.
b. Align the matchmarks on the valve housing and rack housing, and install the valve housing with the valve assembly to the rack housing.
c. Torque the 2 bolts.
Torque: 18 Nm (13 ft. lbs.)
9. Install dust cover.
10. Install rack guide sub-assembly, rack guide spring and rack guide spring cap.
a. Apply sealant to 2 or 3 threads of the cap.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
b. Temporarily install the cap.
11. Adjust total preload.
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.
b. Torque the rack guide spring cap.
Torque: 25 Nm (18 ft. lbs.)





c. Return the cap 19°.





d. Using SST 09616-00010, turn the control valve shaft right and left 1 or 2 times.
e. Loosen the cap until the rack guide spring is not functioning.





f. Using SST and a torque wrench, tighten the cap until the preload is within specification.
Preload (turning): 0.5 - 1.7 Nm (4.1 - 14.9 inch lbs.)





12. Install rack guide spring cap lock nut.
a. Apply sealant to 2 or 3 threads of the nut.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
b. Holding the rack guide spring cap rotating, and using SST 09922-10010, torque the nut.
Torque: 51 Nm (38 ft. lbs.)

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

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

c. Recheck the total preload.
Preload (turning): 0.5 - 1.7 Nm (4.1 - 14.9 inch lbs.)
d. Remove the RH and LH rack ends.
13. Install RH and LH claw washers and rack ends.
a. Install a new washer, and temporarily tighten the rack end.





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





b. Using a spanner to hold the steering rack steady, and using SST, torque the rack end.
Torque: 76 Nm (56 ft. lbs.)

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

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





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

NOTICE: Avoid any impact to the rack.

14. Install RH and LH rack boots, clamps and clips.





a. Ensure that the tube hole is not clogged with grease.

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

b. Install the boot.

NOTICE: Be careful not to damage or twist the boot.





c. Using pliers tighten a new clamp, as shown in the illustration.
15. Install RH and LH tie rod ends and lock nuts.
a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
b. After adjusting toe-in, torque the nut.
Torque: 55 Nm (41 ft. lbs.)





16. Install 2 turn pressure tubes.
a. Install a new union seat to the rack housing.
b. Using SST 09633-00020, install the tube.
Torque: 20 Nm (15 ft. lbs.)

HINT:
- 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.