Disassembly and Assembly

DISASSEMBLY

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





1. REMOVE 2 TURN PRESSURE TUBES
Using SST, remove the 2 turn pressure tubes.
SST 09023-38200





2. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the PS gear assembly in a vise.
SST 09612-00012





3. REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS
a. Place matchmarks on the tie rod end, lock nut and rack end.
b. Loosen the lock nut, and remove the tie rod end and lock nut.
c. Employ the same manner described to the other side.





4. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS
a. Using pliers, loosen the clamp as shown in the illustration.
b. Remove the clamp, clip and rack boot.

NOTICE: Be careful not to damage the boot.

HINT: Mark the RH and LH rack boots.

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





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

NOTICE: Avoid any impact on the steering rack.





b. Using a spanner, 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 to the other side.





6. 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.

7. REMOVE RACK GUIDE SPRING CAP, CONICAL SPRING, RACK GUIDE SPRING AND RACK GUIDE SUB-ASSEMBLY
a. Using a hexagon wrench (24 mm), remove the rack guide spring cap.
b. Remove the conical spring, rack guide spring and rack guide sub-assembly.
8. REMOVE DUST COVER





9. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place matchmarks on the control valve housing and rack housing.
b. Remove the 2 bolts and pull out the control valve housing with control valve assembly.
c. Remove the O-ring from the control valve housing.
10. REMOVE BEARING GUIDE NUT AND CONTROL VALVE ASSEMBLY





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





b. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
c. Using a plastic hammer, tap out the control valve assembly with the bearing guide nut from the control valve housing.

NOTICE: Be careful not to damage the oil seal lip

d. Remove the bearing guide nut from the control valve assembly.
e. Remove the O-ring from the bearing guide nut.





11. REMOVE CYLINDER END STOPPER AND SPACER
a. Using SST, remove the cylinder end stopper.
SST 09631-20090
b. Remove the O-ring from the cylinder end stopper.
c. Remove the spacer.





12. REMOVE STEERING RACK WITH OIL SEAL
a. Using SST, press out the steering rack with the oil seal.
SST 09950-70010 (09951-07200)

NOTICE: Take care not to drop the steering rack.

b. Remove the oil seal from the steering rack.





13. REMOVE OIL SEAL
Using SST, press out the oil seal.
SST 09950-60010 (09951-00250, 09951-00280, 09952-06010) 09950-70010 (09951-07360)

NOTICE: Be careful not to damage the rack housing.

INSPECTION





1. INSPECT STEERING RACK
a. Using a dial indicator, check the steering rack for runout and for teeth wear and damage.
Maximum runout: 0.15 mm (0.0059 inch)
b. Check the back surface for wear and damage.





2. 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.

REPLACEMENT

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

1. IF NECESSARY, REPLACE OIL SEAL AND BEARING





a. Using SST, press out the bearing and oil seal 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 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Make sure that the oil seal is installed facing in the correct direction.

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





e. Using SST, press in the bearing.
SST 09950-60010 (09951-00340), 09950-70010 (09951-07150)
2. IF NECESSARY, REPLACE OIL SEAL





a. Using SST, press out the oil seal from the bearing guide nut.
SST 09950-60010 (09951-00310), 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 (09951-00250, 09951-00360, 09952-06010), 09950-70010 (09951-07100)

NOTICE: Make sure that the oil seal is installed facing in the correct direction.

3. IF NECESSARY, REPLACE UNION SEAT





a. Using a screw extractor, remove the union seat from the control valve housing.





b. Using a plastic hammer and extension bar, lightly tap in a new union seat.





4. 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.





5. 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.
6. 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 teflon 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.





f. Carefully slide the tapered end of SST over the teflon ring until it fits to the steering rack.
SST 09630-24014 (09620-24051)

NOTICE: Be careful not to damage the teflon ring.

7. IF NECESSARY, REPLACE 4 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 teflon ring.

b. Expand 4 new teflon rings with your fingers.

NOTICE: Be careful not to overexpand the teflon ring.

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.

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
2. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid.





b. Install the oil seal to SST, and press them into the rack housing.
SST 09950-60010 (09951-00250, 09951-00430, 09952-06010), 09950-70010 (09951-07360)

NOTICE:
- Make sure that the oil seal is installed 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 rack.
SST 09631-33010

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.
d. Remove the SST.
SST 09631-33010





4. INSTALL OIL SEAL
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 with- out tilting.

NOTICE: Make sure that the oil seal is installed facing in the correct direction.

5. INSTALL CYLINDER END STOPPER AND SPACER
a. Install the spacer.





b. Coat a new O-ring with power steering fluid and install it to the cylinder end stopper.
c. Using a wooden block and hammer, drive in the cylinder end stopper until it is tightly installed.

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





d. Using SST, torque the cylinder end stopper.
SST 09631-20090
Torque: 59 Nm (600 kgf-cm, 44 ft. lbs.)





6. AIR TIGHTNESS TEST
a. Install SST to the rack housing.
SST 09631-12071
b. Apply 53 kPa (400 mm Hg, 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 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 control valve assembly into the control valve housing.

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

8. INSTALL BEARING GUIDE NUT
a. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.





b. Using SST, install the bearing guide nut.
SST 09631-20060
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

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





c. Using a punch, stake the bearing guide nut.





9. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Coat a new O-ring with power steering fluid, and install it to the control valve housing.
b. Align the matchmarks on the valve housing and rack housing.
c. Install the 2 bolts.
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)
10. INSTALL DUST COVER





11. INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING, CONICAL SPRING AND RACK GUIDE SPRING CAP
a. Install the rack guide sub-assembly, rack guide spring and conical spring.

NOTICE: Make sure that the conical spring is installed facing in the correct direction.

b. Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Temporarily install the rack guide spring 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 rack guide spring cap 12°.





d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00011
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 the specification.
SST 09616-00011
Preload (turning): 1.15 - 1.95 Nm (11.7 - 19.9 kgf-cm, 10.2 - 17.3 inch lbs.)





13. 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.08833-00080, 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 (510 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): 1.15 - 1.95 Nm (11.7 - 19.9 kgf-cm, 10.2 - 17.3 inch lbs.)
e. Remove the RH and LH rack ends.
14. 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 claw washer with the steering rack grooves.





b. Using a spanner, hold the steering rack steadily and using SST, torque the rack end.
SST 09922-10010
Torque: 76 Nm (780 kgf-cm, 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 380 mm (14.96 inch).





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

NOTICE: Avoid any impact on the steering rack.

d. Employ the same manner described to the other side.
15. 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 a new clamp.

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

c. Tighten the clamp as shown in the illustration.
d. Employ the same manner described to the other side.





16. 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 to the other side.





17. INSTALL 2 TURN PRESSURE TUBES
Using SST, install the 2 turn pressure tubes.
SST 09023-38200
Torque: 22 Nm (220 kgf-cm, 16 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.