Steering Gear: Service and Repair
Part 1 Of 3:
Part 2 Of 3:
OVERHAUL
NOTICE:
^ When installing, coat the parts indicated by the arrow with power steering fluid or molybdenum disulfide lithium base grease.
^ Remove the steering wheel assembly before the steering gear removal, because there is possibility of breaking of the spiral cable.
^ When using a vise, do not overtighten.
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE FRONT WHEEL
a. Remove the 10 bolts and ornament.
b. Remove the 5 nuts and front wheel.
3. REMOVE SWITCH & VOLUME CASE
4. REMOVE STEERING PAD SWITCH MODULATOR
5. REMOVE STEERING WHEEL COVER LOWER NO.2
6. REMOVE HORN BUTTON ASSY
7. REMOVE STEERING WHEEL ASSY
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09950-05021)
8. SEPARATE TIE ROD ASSY LH
a. Remove the 2 bolts and caliper.
b. Support the brake caliper securely.
c. Remove the clip and nut.
d. Using SST, disconnect the tie rod end from the lower ball joint.
SST 09628-62011
9. SEPARATE TIE ROD ASSY RH
HINT: Employ the same manner described above to the tie rod assy LH.
SST 09628-62011
10. REMOVE ENGINE UNDER COVER NO.2
11. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH
a. Remove the bolt, nut and front suspension member brace rear RH.
12. REMOVE FRONT SUSPENSION MEMBER BRACE REAR LH
a. Remove the bolt, nut and front suspension member brace rear LH.
13. REMOVE FRONT SUSPENSION MEMBER BRACE SUB-ASSY RH
a. Remove the 4 bolts and front suspension member brace sub-assy.
14. SEPARATE STEERING SLIDING YOKE SUB-ASSY
a. Place match-marks on the steering sliding yoke sub-assy and control valve shaft.
b. Loosen the bolt "A" and remove the bolt "B" and disconnect the steering sliding yoke sub-assy.
15. SEPARATE PRESSURE FEED TUBE ASSY
a. Pressure feed tube: Remove the union bolt and gasket.
b. Return tube: Remove the union bolt and 2 gaskets.
HINT: When the tool cannot be easily inserted, loosen the 4 rack and pinion power steering gear assy set bolts and slide the rack and pinion power steering gear assy rearward a little.
16. REMOVE RACK & PINION POWER STEERING GEAR ASSY
a. Remove the 2 bolts and disconnect the 2 tube clamps.
b. Disconnect the connector assy.
c. Remove the 4 gear assy set bolts and rack and pinion power steering gear assy.
d. Remove the steering rack housing bracket No. 2 and Grommet.
17. FIX RACK & PINION POWER STEERING GEAR ASSY
a. Using SST, remove the steering right turn pressure tube and steering left turn pressure tube.
SST 09023-38200
b. Remove the steering turn pressure tube union seat from the power steering rack housing.
c. Using SST, secure the rack and pinion power steering gear assy in a vise, as shown in the illustration.
SST 09612-00012
18. REMOVE TIE ROD ASSY LH
a. Place match-marks on the tie rod assy LH and rack end.
b. Loosen the lock nut, and remove the tie rod assy LH lock nut.
19. REMOVE TIE ROD ASSY RH
HINT: Employ the same manner described above to the tie rod assy LH.
20. INSPECT TIE ROD ASSY LH
a. Secure the tie rod assy LH in a vise.
b. Install the nut to the stud bolt.
c. Flip the ball joint stud back and forth 5 times.
d. Using a torx wrench, turn the nut continuously at a rate of 2 - 4 seconds per 1 turn and take the torque reading of the 5th turn.
Turning torque: 0.49 - 3.43 Nm (5.0 - 35 kgf-cm, 4.34 - 30.38 inch lbs.)
21. INSPECT TIE ROD ASSY RH
HINT: Employ the same manner described above to the tie rod assy LH.
22. REMOVE STEERING RACK BOOT CLIP
23. REMOVE STEERING RACK BOOT NO.1 CLAMP
a. Using pliers, loosen the clamp, as shown in the illustration.
NOTICE: Be careful not to damage the steering rack boot No.1.
24. REMOVE STEERING RACK BOOT NO.2 CLAMP
HINT: Employ the same manner described above to the rack boot No. 1 clamp.
25. REMOVE STEERING RACK BOOT NO.1
a. Remove the clip and steering rack boot No. 1.
HINT: Mark the No. 1 and No. 2 rack boots.
26. REMOVE STEERING RACK BOOT NO.2
HINT: Employ the same manner described above to the steering rack boot No. 1.
27. REMOVE STEERING RACK END SUB-ASSY
a. Using a screwdriver and a hammer, unstake the steering rack end claw washer.
NOTICE: Avoid any impact to the power steering rack.
b. Using a spanner, hold the power 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.
c. Employ the same manner described above to the other side.
HINT: Mark the RH and LH rack ends.
28. REMOVE STEERING RACK END CLAW WASHER
a. Remove the 2 steering rack end claw washers.
29. REMOVE RACK GUIDE
a. Using SST, remove the steering rack guide spring cap nut.
SST 09922-10010
NOTICE: Use SST 09922-10010 in the direction shown in the illustration.
b. Remove steering rack guide spring cap, steering rack guide spring, conical spring washer and steering gear rack guide.
c. Remove the rack guide seat from the steering gear rack guide.
30. REMOVE POWER STEERING CONTROL VALVE
a. Remove steering gear dust cover.
b. Place match-marks on the control valve housing and power steering rack housing.
c. Remove the 2 bolts.
d. Pull out the power steering control valve assembly with the control valve housing.
e. Remove the O-ring from the power steering rack housing.
f. Using SST, loosen the bearing guide nut.
SST 09631-20060
g. Wind vinyl tape to the control valve shaft.
h. Using a plastic hammer, tap out the power steering control valve assembly with the bearing guide nut from the control valve housing.
NOTICE: Be careful not to damage the oil seal lip.
i. Remove the bearing guide nut from the power steering control valve assembly.
NOTICE: Be careful not to damage the oil seal lip.
j. Remove the O-ring from the bearing guide nut.
k. Using a screwdriver, remove the 4 power steering control valve rings from the control valve assembly.
NOTICE: Be careful not to damage the grooves for the power steering control valve ring.
31. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL
a. Using SST, press out the power steering control valve upper oil seal and bearing from the control valve housing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07150)
32. REMOVE POWER STEERING CONTROL VALVE LOWER OIL SEAL
a. Using SST, press out the power steering control valve lower oil seal from the bearing guide nut.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)
33. INSPECT POWER STEERING CONTROL VALVE
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.
34. REMOVE CYLINDER END STOPPER
a. Using SST, remove the cylinder end stopper.
SST 09631-20090
b. Remove the O-ring from the cylinder end stopper.
35. INSPECT CYLINDER END STOPPER
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.
36. REMOVE POWER STEERING RACK
a. Using SST and a press, press out the steering rack, power steering cylinder housing spacer and power steering rack housing oil seal.
NOTICE: Take care not to drop the power steering rack.
SST 09950-70010 (09951-07200)
b. Remove the power steering cylinder housing spacer and power steering rack housing oil seal from the power steering rack.
c. Install SST (09612-07130) on SST (09612-07210).
SST 09612-70100 (09612-07130, 09612-07210)
NOTICE:
^ Before using them, apply a small dab of grease to the inside wall of SST (09612-07210, 09612-07130).
^ To prevent the inside of the housing from being damaged securely install SST 09612-07130) on SST (09612-07210).
d. Diagonally insert SST (09612-07210) into the housing until it contacts with the oil seal, and then further insert the SST (09612-07210) until the tip of SST (09612-07220) contacts with SST (09612-07130).
SST 09612-70100 (09612-07130, 09612-07210. 09612-07220)
NOTICE: Do not damage the inside of the housing.
e. Secure SST (09612-07220), and pull SST (09612-07210) to place SST (09612-07130) in the housing.
SST 09612-70100 (09612-07130, 09612-07210, 09612-07220)
HINT: Place SST on the chamfering position between the oil seal and rack housing.
f. Remove the SST (09612-07210, 09612-07220).
SST 09612-70100 (09612-07210, 09612-07220)
g. After installing SST (09612-07240) on SST (09612-07210), insert the tip of SST (09612-07230) in the service hole of SST (09612-07130).
SST 09612-70100 (09612-07130, 09612-07230, 09612-07240)
NOTICE:
^ Before using them, apply a small dab of grease to the tip of SST (09612-07230).
^ To prevent SST (09612-07130) from being damaged, be sure to install SST (09612-07240).
^ Do not damage the inside of the rack housing.
h. Install SST (09951-07100) on SST (09612-07230) and remove the oil seal using a press.
SST 09612-70100 (09612-07130, 09612-07230, 09612-07240), 09950-70010 (09951-07100)
NOTICE: Do not damage the rack housing.
HINT: Replace SST (09951-07100) with SST that is different in length in the set, if necessary.
37. REMOVE POWER PISTON OIL SEAL
a. Using a screwdriver, remove the power piston oil seal and O-ring from the steering rack.
NOTICE: Be careful not to damage the groove for the power piston oil seal.
38. INSPECT POWER STEERING RACK
a. Using a dial indicator, check the steering 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.
39. INSPECT POWER STEERING CONTROL VALVE LOWER BEARING
a. Check the bearing of the rack housing for pit-marks or damage.
If faulty, replace the rack and pinion power steering gear assy.
40. INSTALL POWER PISTON OIL SEAL
a. Coat a new O-ring with power steering fluid and install it.
b. Expand a new power piston oil seal with your finger.
NOTICE: Be careful not to over expand the power piston oil seal.
c. Coat the ring with power steering fluid.
d. Install the power piston oil seal to the power steering rack, and settle it down with your fingers.
41. INSTALL POWER STEERING RACK HOUSING OIL SEAL
a. Apply power steering fluid to a new oil seal, and install the oil seal on the rack housing at an angle.
NOTICE: Install the oil seal in the correct direction.
HINT: Install the oil seal so that the port faces downward with approximately 15 degrees.
b. Using SST, push in the oil seal by hand until it passes through the 2 ports.
SST 09631-00180, 09950-70010 (09951-07360)
NOTICE: Do not turn SST when inserting the oil seal.
c. After the oil seal has passed through the ports, push in the oil seal by hand until it becomes level, using SST.
SST 09950-60010 (09951-00490), 09950-70010 (09951-07360)
NOTICE: When SST is set, do not damage the inside surface of the rack housing.
d. After the oil seal has become level, using SST and press, install the oil seal.
SST 09950-60010 (09951-00490), 09950-70010 (09951-07360)
e. Install SST to the power steering rack sub-assy. SST 09631-20102
NOTICE: If necessary, scrape the burrs off the steering rack teeth end and burnish.
f. Coat the SST with fluid.
g. Install the power steering rack sub-assy into the power steering rack housing sub-assy.
NOTICE: Be careful not to damage the oil seal lip.
h. Remove the SST.
SST 09631-20102
i. Install SST to the power steering rack sub-assy opposite end.
SST 09631-20102
j. Coat SST with power steering fluid.
k. Coat a new power steering rack housing oil seal lip with power steering fluid.
l. Install the power steering rack housing oil seal by pushing it onto the SST without tilting.
NOTICE: Make sure that the oil seal is installed facing in the correct direction.
m. Remove the SST.
SST 09631-20102
n. Using SST and a hammer, drive in the power steering cylinder housing spacer.
SST 09950-60010 (09951-00280, 09951-00420, 09952-06010), 09950-70010 (09951-07200)
42. INSTALL CYLINDER END STOPPER
a. Coat a new O-ring with power steering fluid, and install it to the cylinder end stopper.
b. Using a wooden block and a hammer, drive in the cylinder end stopper until it is tightly installed.
NOTICE: Be careful not to damage the O-ring.
c. Using SST, torque the cylinder end stopper.
SST 09631-20120
Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.)
43. AIR TIGHTNESS TEST
a. Install the SST to the unions of the power steering 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 change in the vacuum, check the installation of the oil seals.
44. INSTALL POWER STEERING CONTROL VALVE LOWER OIL SEAL
a. Coat a new power steering control valve lower oil seal lip with power steering fluid.
b. Using SST, press in the power steering control valve lower oil seal.
SST 09950-60010 (09951-00280, 09951-00360, 09952-06010), 09950-70010 (09951-07100)
NOTICE: Make sure that the oil seal is installed facing in the correct direction.
45. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL
a. Coat a new power steering control valve upper oil seal lip with power steering fluid.
b. Using SST, press in the power steering control valve upper oil seal.
SST 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150)
c. Coat a bearing with molybdenum disulfide lithium base grease.
d. Using SST, press in the bearing.
SST 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150)
46. INSTALL POWER STEERING CONTROL VALVE
a. Coat the power steering control valve rings with power steering fluid.
b. Install the power steering control valve rings to the power steering control valve sub-assy, and settle them down with your fingers.
c. Carefully slide the tapered end of SST over the power steering control valve rings until the power steering control valve ring fits to the power steering rack.
SST 09631-20081
NOTICE: Be careful not to damage the power steering control valve rings.
d. Coat the power steering control valve rings with power steering fluid.
e. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
f. Push the power steering control valve assembly into the control valve housing.
NOTICE: Be careful not to damage the power steering control valve rings and oil seal lip.
g. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.
h. Using SST, torque 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.
i. Using a punch, stake the bearing guide nut.
j. Coat a new O-ring with power steering fluid, and install it to the control valve housing.
k. Align the match-marks on the control valve housing and power steering rack housing, and install the control valve housing with the control valve assembly to the power steering rack housing.
l. Install the 2 bolts.
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)
m. Install steering gear dust cover.
47. INSTALL RACK GUIDE
a. Install the rack guide seat to the steering gear rack guide.
b. Install the rack guide sub-assembly, conical spring washer and steering rack guide spring.
c. Apply sealant to 2 or 3 threads of the steering rack guide spring cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
d. Temporarily install the rack guide spring cap.
48. ADJUST TOTAL PRELOAD
a. To prevent the power steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH steering rack end sub-assys.
b. Torque the steering rack guide spring cap.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
c. Return the steering rack guide spring cap 17°.
d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00011
e. Loosen the steering rack guide spring cap until the steering rack guide spring is not functioning.
f. Using SST and a torque wrench, tighten the steering rack guide spring cap until the preload is within specification.
SST 09616-00011
Preload (turning): 0.5 - 1.7 Nm (4.7 - 17.2 kgf-cm, 4.1 - 14.9 inch lbs.)
g. Apply sealant to 2 or 3 threads of the steering rack guide spring cap nut.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
h. Holding the steering rack guide spring cap rotating, and using SST, torque the steering rack guide spring nut.
SST 09922-10010
Torque: 51 Nm (520 kgf-cm, 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).
i. Recheck the total preload.
Preload (turning): 0.5 - 1.7 Nm (4.7 - 17.2 kgf-cm, 4.1 - 14.9 inch lbs.)
j. Remove the RH and LH steering rack end sub-assys.
49. INSTALL STEERING RACK END CLAW WASHER
a. Install a new claw washer, and temporarily tighten the rack end.
HINT: Align the claws of the steering rack end claw washer with the steering rack grooves.
b. Employ the same manner described above to the other side.
50. INSTALL STEERING RACK END SUB-ASSY
a. Using a spanner, hold the power steering rack steadily, and using SST, torque the steering rack end sub-assy.
SST 09922-10010
Torque: 76 Nm (770 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 345 mm (13.58 inch).
b. Using a brass bar and a hammer, stake the steering rack end claw washer.
NOTICE: Avoid any impact to the rack.
c. Employ the same manner described above to the other side.
51. INSTALL STEERING RACK BOOT NO.1
a. Ensure that the steering rack hole is not clogged with grease.
HINT: If the tube hole is clogged, the pressure inside the boot sill change after it is assembled and the steering wheel is turned.
b. Instal the steering rack boot No. 1.
52. INSTALL STEERING RACK BOOT NO.2
HINT: Employ the same manner described above to the steering rack boot No. 1.
53. INSTALL STEERING RACK BOOT NO.1 CLAMP
a. Instal a new steering rack boot No. 1 clamp.
NOTICE: Be careful not to damage or twist the rack boot.
b. Using plies tighten a new clamp, as shown in the illustration.
54. INSTALL STEERING RACK BOOT NO.2 CLAMP
HINT: Employ the same manner described above to the rack boot No. 1 clamp.
55. INSTALL STEERING RACK BOOT CLIP
a. Using pliers, install 2 steering rack boot clips.
NOTICE: Be careful not to damage or twist the rack boot.
56. INSTALL TIE ROD ASSY LH
a. Screw the lock nut and tie rod assy LH onto the steering rack end sub-assy until the match-marks are aligned.
b. After adjusting toe-in, torque the nut.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
57. INSTALL TIE ROD ASSY RH
HINT: Employ the same manner described above to the tie rod assy LH.
58. INSTALL RACK & PINION POWER STEERING GEAR ASSY
a. Install 2 new steering turn pressure tube union seats to the rack housing.
b. Using SST, install the steering left turn pressure tube and steering right turn pressure tube.
SST 09023-38200
Torque: 23 Nm (240 kgf-cm, 17 ft. lbs.)
HINT:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
^ This torque valve is effective in case that SST is parallel to a torque wrench.
c. Install the grommet and steering rack housing bracket No. 2 to the rack and pinion power steering gear assy.
d. Install the rack and pinion power steering gear assy with the 4 gear assy set bolts.
Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)
e. Connect the connector.
f. Connect the 2 tube clamps with the bolt.
Torque. 23 Nm (240 kgf-cm, 17 ft. lbs.)
59. CONNECT STEERING SLIDING YOKE SUB-ASSY
60. CONNECT PRESSURE FEED TUBE ASSY
a. Pressure feed tube:
Connect the pressure feed tube and a new gasket with the union bolt.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Return tube:
Connect the return tube and 2 new gaskets with the union bolt.
Torque: 49 Nm (250 kgf-cm, 36 ft. lbs.)
61. CONNECT TIE ROD ASSY LH
a. Connect the tie rod assy to the lower ball joint and install the clip and nut.
Torque: 87 Nm (890 kgf-cm, 64 ft. lbs.)
b. Install the 2 nuts and caliper.
Torque: 118 Nm (1200 kgf-cm, 87 ft. lbs.)
62. CONNECT TIE ROD ASSY RH
HINT: Employ the same manner described above to the other side.
63. INSPECT CENTER FRONT WHEEL
HINT: Do it with the front of the vehicle jacked up.
64. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSY RH
a. Install the front suspension member brace sub-assy and 4 bolts.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)
65. INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH
a. Install the front suspension member brace rear LH, bolt and nut.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)
66. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
a. Install the front suspension member brace rear RH, bolt and nut.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)
67. INSTALL ENGINE UNDER COVER NO.2
68. CENTER SPIRAL CABLE
69. TEMPORARILY TIGHTEN STEERING WHEEL ASSY
a. Align the match-marks on the wheel and steering column main shaft.
b. Temporarily tighten the steering wheel set nut
c. Connect the connector.
70. BLEED POWER STEERING SYSTEM
71. INSPECT STEERING WHEEL CENTER POINT
72. FULLY TIGHTEN STEERING WHEEL SET NUT
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
73. INSTALL HORN BUTTON ASSY
74. INSTALL STEERING WHEEL COVER LOWER NO.2
75. INSTALL STEERING PAD SWITCH MODULATOR
76. INSTALL SWITCH & VOLUME CASE
77. INSTALL FRONT WHEEL
a. Install the front wheel with the 5 nuts.
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
b. Install the ornament with the 10 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
78. INSPECT TIRE
79. INSPECT TOE-IN
80. ADJUST TOE-IN
81. INSPECT WHEEL ANGLE
82. DRIVING TEST