Disassembly and Assembly

DISASSEMBLY

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





1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the steering gear assembly in a vise.
SST 09612-00012
2. REMOVE 2 TURN PRESSURE TUBES
a. Remove the union bolt and 2 gaskets.





b. Using SST, remove the tube. SST 09633-00020
c. Remove the 2 union seats from the rack housing.





3. REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS
Place matchmarks on the tie rod end and rack end, and loosen the lock nut.
4. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS
Remove the screw and loosen the clamp.

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 chisel and a hammer, unstake the washer.

NOTICE: Avoid any impact on the steering rack.





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

NOTICE:
- Use SST 09922-10010 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.
SST 09922-10010

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

7. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING, RACK GUIDE SUB-ASSEMBLY
Using a hexagon wrench (24 mm), remove the cap.
8. REMOVE RACK HOUSING CAP





9. REMOVE SELF-LOCKING NUT, LOWER BEARING AND SPACER
Using SST to stop the control valve shaft rotating, remove the nut.
SST 09610-00010
10. REMOVE DUST COVER





11. REMOVE CONTROL VALVE HOUSING WITH 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 hexagon wrench (6 mm), remove the 2 bolts.
c. Remove the O-ring from the housing.





12. REMOVE CONTROL VALVE ASSEMBLY
Using a plastic hammer, tap out the control valve.

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

13. REMOVE CYLINDER END STOPPER AND SPACER
Using snap ring pliers, remove the snap ring from the rack housing.





14. REMOVE STEERING RACK AND OIL SEAL
a. Using an extension bar or brass bar and a press, press out the rack with the oil seal.

NOTICE: Take care not to drop the rack.

b. Remove the oil seal from the rack.





15. REMOVE OIL SEAL
Using SST, press out the oil seal.
SST 09950-60010 (09951-00280), 09950-70010 (09951-07200)


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 or damage.
Maximum runout: 0.30 mm (0.0118 inch)
b. Check the back surface for wear or damage.
2. IF NECESSARY, REPLACE OIL SEAL AND BEARING





a. Set SST to the rack housing, as shown in the illustration.
SST 09612-30012
b. Turn A clockwise and engage the tips of C on the bearing.
c. Using a spanner (8 mm), keep A fixed while turning nut B clockwise, and remove the bearing.

NOTICE: Be careful not to damage the rack housing.





d. 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.





e. Coat a new oil seal lip with power steering fluid.
f. 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 the correct direction.





g. Using SST, press in the bearing.
SST 09950-60010 (09951-00460), 09950-70010 (09951-7100)
3. IF NECESSARY, REPLACE OIL SEAL AND BEARING





a. Using SST, press out the oil seal with the 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 the correct direction.





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

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





c. Expand a new teflon ring with your finger

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.
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 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 over the rings until the rings fit to the control valve assembly.
ST 09631-20081

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 rings from the control valve assembly.

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

b. Coat 2 new O-rings with power steering fluid, and install them.
c. Expand 2 new teflon rings with your fingers.

NOTICE: Be careful not to overexpand the teflon rings.

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





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

NOTICE: Be careful not to damage the teflon rings.

7. IF NECESSARY, REPLACE PRESSURE CONTROL VALVE ASSEMBLY
a. Using a hexagon wrench (6 mm), remove the 3 bolts and connector bracket.
b. Remove the 3 O-rings from the control valve housing.
c. Coat 3 new O-rings with power steering fluid, and install them.
d. Using a hexagon wrench (6 mm), install a new pressure control valve and connector bracket with the 3 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)


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, 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 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 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 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. To prevent oil seal lip damage, wind vinyl tape on the steering rack, 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.

NOTICE:
^ Make sure to install the oil seal facing the connect direction.
^ Be careful not to damage the oil seal lip.

d. install the spacer into the rack housing.





5. INSTALL CYLINDER END STOPPER
a. Using SST and a hammer, drive in the stopper.
SST 09950-60010 (09951-00310), 09950-70010 (09951-07200)
b. Using snap ring pliers, install the snap ring to the rack housing.





6. AIR TIGHTNESS TEST
a. Install SST to the rack housing. SST 09631-12071

NOTICE: Do not install union seats.

b. Apply 53.3 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 with power steering fluid.
b. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control 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 WITH CONTROL VALVE ASSEMBLY
Coat a new O-ring with power steering fluid and install it to the housing.
b. Using a hexagon wrench (6 mm), torque the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
9. INSTALL LOWER BEARING, SPACER AND SELF-LOCKING NUT





Using SST to stop the control valve shaft rotating, torque a new nut.
SST 09616-00010
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
10. INSTALL RACK HOUSING CAP
a. Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No. 088300080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Torque the cap.
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)
11. 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: Part No. 088300080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Temporarily install the cap.
12. 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 cap 12°.
d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00010

e. Using a hexagon wrench (24 mm), loosen the cap until the rack guide spring is not functioning.





f. Using SST, a torque wrench and hexagon wrench (24 mm), tighten the cap until the preload is within the specification.
SST 09616-00010
Preload (turning): 0.8 - 1.7 Nm (8 - 17 kgf-cm, 6.9 - 14.8 inch lbs.)

13. INSTALL RACK GUIDE SPRING CAP LOCK NUT
a. Apply sealant to 2 or 3 threads of the nut.
Sealant: Part No. 08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent





b. Using a hexagon wrench (24 mm) hold the rack guide spring cap, and using SST torque the 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).

c. Recheck the total preload.
Preload (turning): 0.8 - 1.7 Nm (8 - 17 kgf-cm, 6.9 - 14.8 inch lbs.)
d. Remove the RH and LH rack ends.
14. INSTALL DUST COVER
15. 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 spanner (22 mm) 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 a hammer, stake the washer.

NOTICE: Avoid any impact on the rack.





16. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS
a. Make sure 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 with the screw.
17. 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.)
18. INSTALL 2 TURN PRESSURE TUBES
a. Install the 2 union seats.





b. Using SST, install the tube.
SST 09633-00020
Torque: 24 Nm (243 kgf-cm, 18 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.

c. Torque the union bolt over 2 new gaskets.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)