Disassembly and Assembly

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

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

DISASSEMBLY

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

1. Secure PS gear assembly in vise.
a. Using Special Service Tool (SST) 09612 - 00012 or equivalent, secure the gear assembly in a vise.
b. Remove the tube clamp.





2. Remove pressure control valve.
a. Using a hexagon wrench (6 mm), remove the 3 bolts.
b. Remove the 4 O-rings from pressure control valve.





3. Remove 2 turn pressure tubes.
Using SST 09633 - 00020, remove the tube.





4. Remove RH and LH tie rod ends and lock nuts.
a. Place matchmarks on the tie rod end and rack end.
b. Loosen the lock nut.
5. Remove RH and LH clips, rack boots and clamps.

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





6. Remove RH and LH rack ends and claw washers.
a. Using a screwdriver and hammer, unstake the washer.

NOTICE: Avoid any impact to the steering rack.

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





NOTICE: Use SST 03922 - 10010 in the direction shown in the illustration.

7. Remove rack guide spring cap lock nut.
Using SST 09922 - 10010, remove the nut.





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

8. Remove rack guide spring cap, rack guide spring, rack guide subassembly.
Using a 24 mm hexagon wrench, remove the cap.
9. Remove rack housing cap.





10. Remove self-locking nut. Using SST 09616 - 00010 to stop the control valve shaft rotating, remove the nut.

11. Remove dust cover.
12. Remove control valve housing with control valve assembly.
a. Using a hexagon wrench (6 mm), remove the 2 bolts.
b. Pull out the valve with the valve housing.
c. Remove the O-ring from the valve housing.





13. Remove control valve assembly.
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
b. Using a plastic hammer, tap out the valve assembly.
14. Remove bearing and spacer.
Remove the bearing and spacer from the rack housing.
15. Remove cylinder end stopper, spacer, oil seal and steering rack.
a. Using snap ring pliers, remove the snap ring from the rack housing.





b. Using a brass bar, press the rack until the end stopper slightly touches the press block.
c. Pull out the rack with the cylinder end stopper, spacer and oil seal.

HINT: If necessary, slightly tap the rack end with a brass bar and hammer.





16. Remove oil seal.
Using SST 09950 - 60010 (09951 - 00310), 09950 - 70010 (09951 - 07360), press out the oil seal.

INSPECTION

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





1. Inspect steering rack.
a. Using a dial indicator, check the rack for runout and for teeth wear and damage.
Maximum runout: 0.30 mm (0.0118 inch).
b. Check the back surface for wear and damage.





2. If necessary, replace bearing and oil seal.
a. Using SST 09612 - 30012, remove the bearing from the rack housing.

NOTICE: Be careful not to damage the rack housing.





b. Using SST 09612 - 30012, remove the oil seal from the rack housing.

NOTICE: Be careful not to damage the rack housing.

HINT: When using SST, apply the tips of SST to the cutouts in the rack housing.

c. Coat a new oil seal lip with power steering fluid.





d. Using SST 09950 - 60010 (09951 - 00280, 09951 - 00400, 09952 - 06010), 09950 - 70010 (09951 - 07100), press in the oil seal.

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





e. Using SST 09950 - 60010 (09951 - 00460), 09950 - 70010 (09951 - 07100), press in the bearing.





3. If necessary, replace bearing and oil seal.
a. Using SST 09950 - 60010 (09951 - 00240), 09950 - 70010 (09951 - 07100), press out the oil seal and bearing from the control valve housing.
b. Coat a new oil seal lip with power steering.





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

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





d. Using SST 09950 - 60010 (09951 - 00340), 09950 - 70010 (09951 - 07200), press in the bearing.





4. 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 steering rack and snug it down with your fingers.





5. 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 Teflon rings with your fingers.

NOTICE: Be careful not to overexpand the ring. Coat the rings with power steering fluid. Install the rings to the control valve assembly, and snug Them down with your fingers.





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

NOTICE: Be careful not to damage the rings.





6. If necessary, replace Teflon rings and O-rings.
a. Using a screwdriver, remove the 2 Teflon rings and O-rings from the control valve assembly.

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

b. Coat 2 new O-rings with power steering fluid and install them to the valve assembly.
c. Expand 2 new Teflon rings with your fingers.

NOTICE: 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 SST 09631 - 32020 over the rings to seat them.

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 polybdenum-disulfide lithium base grease.
2. Install oil seal.
a. Coat a new oil seal lip with power steering fluid.





b. Using SST 09950 - 60010 (09951 - 00240, 09951 - 00430, 09952 - 06010), 09550 - 70010 (09951 - 07360), press in the oil seal.

NOTICE:
- Make sure you 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 off the rack teeth end and burnish.

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

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

d. Remove the SST.
4. Install oil seal and spacer.
a. Coat a new oil seal lip with power steering fluid.





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

NOTICE:
- Make sure you install the oil seal facing the correct direction.
- Be careful not to damage the oil seal lip.

d. Install the spacer.





5. Install cylinder end stopper.
a. Using SST 09612 - 22011 and a hammer, drive in the stopper.

b. Using snap ring pliers, install the snap ring.





6. Air tightness test.
a. Install SST 09631 - 12071 to 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 valve shaft.
c. Install the valve assembly into the valve housing.

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

8. Install control valve housing.
a. Coat a new O-ring with power steering fluid and install it to the valve housing.
b. Using a 6 mm hexagon wrench, torque the 2 bolts to 18 Nm (13 ft. lbs.)
9. Install dust cover.
10. Install bearing and spacer.
Install the spacer and a new bearing to the rack housing.





11. Install self-locking nut.
Using SST 09616 - 00010 to stop the control valve shaft rotating, torque a new nut.
Torque: 39 Nm (29 ft. lbs.).
12. Install rack housing cap.
a. Apply sealant, THREE BOND 1344, LOCTITE 242, or equivalent, to 2 or 3 threads of the cap.
b. Torque the cap.
Toque: 69 Nm (51 ft. lbs.)
13. Install rack guide seat, rack guide, rack guide spring and rack guide spring cap.
a. Apply sealant THREE BOND 1344, LOCTITE 242, or equivalent to 2 or 3 threads of the spring cap.
b. Temporarily install the cap.





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





d. Using SST 09616 - 00010, turn the control valve shaft right and left 1 or 2 times.
e. Using a 24 mm hexagon wrench, loosen the cap until the rack guide spring is not functioning.





f. Using SST 09616 - 00010, a torque wrench and a 24 mm hexagon wrench, tighten the cap until the preload is within specification.
Preload (turning): 0.9 - 1.2 Nm (7.8 - 10.4 inch lbs.)
15. Install rack guide spring cap lock nut.
a. Apply sealant part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242, or equivalent, to 2 or 3 threads of the nut.
b. Using a 24 mm hexagon wrench to hold the rack guide spring cap, and using SST 09922 - 100 1 0, torque the nut to 50 Nm (37 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): 0.9 - 1.2 Nm (7.8 - 10.4 inch lbs.)
d. Remove the RH and LH rack ends





16. Install RH and LH claw washers and rack ends.
a. Install a new claw washer, and temporarily install the rack end.

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

b. Using a wrench to hold the steering rack steady, and using SST 09922 - 100 1 0, torque the rack end to 77 Nm (57 ft. lbs.).

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

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





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

NOTICE: Avoid any impact to the rack.





17. Install RH and LH rack boots, clamps and clips.
a. Ensure that the steering rack hole is not clogged with grease.

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

b. Install the boot.

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





c. Tighten the clamp as shown in the illustration.
18. 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 to 56 Nm (41 ft. lbs.)





19. Install 2 turn pressure tubes.
a. Using SST 09633 - 00020, install the tube and tighten to 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.

b. Install the tube clamp.





20. Install pressure control valve.
a. Coat 4 new O-rings with power steering fluid and install them to the pressure control valve.
b. Using hexagon wrench (6 mm), torque the 3 bolts.
Torque: 18 Nm (13 ft. lbs.)