Disassembly and Assembly

DISASSEMBLY

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





1. SECURE PS GEAR ASSEMBLY IN VISE
a. Using SST, secure the PS gear assembly in a vise.
SST 09612-00012
b. Remove the tube clamp.





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





3. REMOVE 2 TURN PRESSURE TUBES
Using SST, remove the 2 turn pressure tubes.
SST 09633-00020





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 and remove the tie rod end and lock nut.
c. Employ the same manner described above to the other side.
5. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS
a. Remove the screw and loosen the clamp.

NOTICE: Be careful not to damage the boot.

b. Remove the clip and rack boot.

HINT: Mark the RH and LH rack boots.

c. Employ the same manner described above to the other side.
6. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS





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

NOTICE: Avoid any impact on the steering rack.





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

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

HINT: Mark the RH and LH rack ends.

c. Remove the claw washer.
d. Employ the same manner described above to the other side.





7. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the rack guide spring cap lock nut.
SST 09922-10010

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

8. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING, RACK GUIDE SUB-ASSEMBLY
a. Using a hexagon wrench (24 mm), remove the rack guide spring cap.
b. Remove the rack guide spring and rack guide sub-assembly.
9. REMOVE RACK HOUSING CAP





10. REMOVE SELF-LOCKING NUT
Using SST, stop the control valve shaft rotating and remove the self-locking nut.
SST 09616-00010
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 control valve housing with control valve assembly.
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 control valve shaft.
b. Using a plastic hammer, tap out the control 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 steering rack until the cylinder end stopper slightly touches the press block.
c. Pull out the steering 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, press out the oil seal.
SST 09950-60010 (09951-00310), 09950-70010 (09951-07360)


INSPECTION

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

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.


REPLACEMENT

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

1. IF NECESSARY, REPLACE BEARING AND OIL SEAL





a. Using SST, remove the bearing from the rack housing.
SST 09612-30012

NOTICE: Be careful not to damage the rack housing.





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

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

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





e. Using SST, press in a new bearing.
SST 09950-60010 (09951-00460), 09950-70010 (09951-07100)
2. IF NECESSARY, REPLACE BEARING AND OIL SEAL





a. Using SST, press out the oil seal and bearing from the control valve housing.
SST 09950-60010 (09951-00240), 09950-70010 (09951-07100)





b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07200)

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





d. Using SST, press in a new bearing.
SST 09950-60010 (09951-00340), 09950-70010 (09951-07200)
3. IF NECESSARY, REPLACE TEFLON RING AND 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 to the steering rack.





c. Expand a new teflon ring with your fingers.

NOTICE: Be careful not to overexpand the teflon ring.





d. Coat the teflon ring with power steering fluid.
e. Install the teflon ring to the steering rack and settle it down with your fingers.
4. IF NECESSARY, REPLACE TEFLON RINGS





a. Using a screwdriver, remove the 4 teflon 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 teflon rings.

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





e. Carefully slide the tapered end of SST over the teflon rings until they fit to the control valve assembly. SST 09631 - 20081

NOTICE: Be careful not to damage the teflon rings.

5. IF NECESSARY, REPLACE TEFLON RINGS AND O-RINGS





a. Using a screwdriver, remove the 2 teflon rings and 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 control valve assembly.
c. Expand 2 new teflon rings with your fingers.

NOTICE: Be careful not to overexpand the teflon rings. Coat the teflon rings with power steering fluid.

e. Install the teflon rings to the control valve assembly, and settle them down with your fingers.





f. Carefully slide the tapered end of SST over the rings until they fit to the control valve assembly.
SST 09631-32020

NOTICE: Be careful not to damage the rings.

REASSEMBLY

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

1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE. Refer to Diagrams; Exploded Views.





2. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST, press in the oil seal.
SST 09950-60010 (09951-00240, 09951-00430, 09952-06010), 09950-70010 (09951-07360)

NOTICE:
^ Make sure to install the oil seal facing in the correct direction.
^ Take care that the oil seal does not get reversed as you install it.





3. INSTALL STEERING RACK
a. Install SST to the steering rack.
SST 09631-20102

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

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

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

d. Remove the SST.
SST 09631-20102





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 to install the oil seal facing in the correct direction.
^ Be careful not to damage the oil seal lip.

d. Install the spacer.





5. INSTALL CYLINDER END STOPPER
a. Using SST and a hammer, drive in the cylinder end stopper.
SST 09612-22011
b. Using snap ring pliers, install the snap ring.





6. AIR TIGHTNESS TEST
a. Install SST to the rack housing.
SST 09631-12071
b. Apply 53 kPa (400 mmHg, 15.75 in.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 of the control valve assembly with power steering fluid.
To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
b. Install the control valve assembly into the control 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 control valve housing.
b. Using a hexagon wrench (6 mm), install the control valve housing with the 2 bolts.
Torque: 18 Nm (185 kgf-cm,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, stop the control valve shaft rotating and install a new self-locking nut.
SST 09616-00010
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
12. INSTALL RACK HOUSING CAP
a. Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Install the rack housing cap.
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)
13. INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
a. Install the rack guide sub-assembly and rack guide spring.
b. Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant: Part No. 088300080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Temporarily install the rack guide spring 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 hexagon wrench (24 mm), torque the rack guide spring cap.
Torque: 25 Nm (250 kgf-cm,18 ft. lbs.)





c. Using a hexagon wrench (24 mm), return the rack guide spring cap 12°.





d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09610-00010
e. Using a hexagon wrench (24 mm), loosen the rack guide spring cap until the rack guide spring is not functioning.





f. Using SST, a torque wrench and hexagon wrench (24 mm), tighten the rack guide spring cap until the preload is within specification.
SST 09610-00010
Preload (turning): 0.9 - 1.2 Nm (9 - 12 kgf-cm, 7.8 - 10.4 inch lbs.)
15. INSTALL RACK GUIDE SPRING CAP LOCK NUT
a. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.
Sealant: Part No. 088330080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Temporarily install the rack guide spring cap lock nut.





c. Using a hexagon wrench (24 mm), hold the rack guide spring cap and using SST, torque the rack guide spring cap lock nut.
SST 09922-10010
Torque: 50 Nm (513 kgf-cm, 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).

d. Recheck the total preload.
Preload (turning): 0.9 - 1.2 Nm (9 - 12 kgf-cm, 7.8 - 10.4 inch lbs.)
e. 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, hold the steering rack steadily and using SST, torque the rack end.
SST 09922 - 10010
Torque: 77 Nm (782 kgf-cm, 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 on the steering rack.

d. Employ the same manner described above to the other side.
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, clip and clamp.

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





c. Tighten the clamp with the screw as shown in the illustration.
d. Employ the same manner described above to the other side.
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.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
c. Employ the same manner described above to the other side.





19. INSTALL 2 TURN PRESSURE TUBES
a. Using SST, install the 2 turn pressure tubes.
SST 09633-00020
Torque: 20 Nm (203 kgf-cm, 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), install the pressure control valve with the 3 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)