Disassembly and Assembly

DISASSEMBLY

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

1. REMOVE 2 TURN PRESSURE TUBES





a. Using SST, remove the 2 turn pressure tubes.
SST 09023-38201
b. Remove the 2 union seats from the rack housing.





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





3. 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.





4. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS
a. Using pliers, loosen the clamp, as shown in the illustration.

NOTICE: Be careful not to damage the boot.

b. Remove the clip and rack boot.
c. Employ the same manner described above to the other side.

HINT: Mark the RH and LH rack boot.

5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS





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

NOTICE: Avoid any impact to 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.

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

HINT: Mark the RH and LH rack ends.





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
8. REMOVE RACK GUIDE SPRING AND RACK GUIDE SUB-ASSEMBLY
9. REMOVE DUST COVER





10. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place matchmarks on the control valve housing and rack housing.
b. Remove the 2 bolts
c. Pull out the control valve assembly with the valve housing.
d. Remove the O-ring from the rack housing.
11. REMOVE CONTROL VALVE ASSEMBLY





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





b. Wind vinyl tape to 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.

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

e. Remove the O-ring from the bearing guide nut.
12. REMOVE CYLINDER END STOPPER AND SPACER





a. Using SST, remove the cylinder end stopper stopper.
SST 09631-20090
b. Remove the O-ring from the cylinder end stopper stopper.
13. REMOVE STEERING RACK AND OIL SEAL





a. Using SST, press out the steering rack and oil seal.

NOTICE: Take care not to drop the steering rack.

SST 09950-70010 (09951-07200)
b. Remove the oil seal from the steering rack.
14. REMOVE OIL SEAL





a. 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).





b. Diagonally insert SST (09612 - 07210) into the housing until it contacts with the oil seal, and then further insert 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.





c. 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.

d. Remove the SST (09612-07210, 09612-07220).
SST 09612-70100 (09612-07210, 09612-07220)





e. 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.





f. 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 (09950-07100)

NOTICE: Do not damage the rack housing.

HINT: Replace SST (09951-07100) with SST that is different in length in the set, if necessary.

INSPECTION





1. INSPECT STEERING RACK
a. Using a dial indicator, check the steering rack for runout and for teeth wear and damage.
Maximum runout: 0.03 mm (0.0118 inch)
b. Check the back surface for wear and damage.





2. INSPECT BEARING
a. Check the needle roller bearing of the rack housing for pitmarks or damage.
If faulty, replace the rack housing.
b. Coat the inside of the bearing with molybdenum disulfide lithium base grease





3. 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
1. IF NECESSARY, REPLACE OIL SEAL AND BEARING





a. Using SST, press out the oil seal and bearing from the control valve housing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07150)
b. Coat a new oil seal lip with power steering fluid.





c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00330, 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 (09951-00330), 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 (09951-00320), 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 (09951-00280, 09951-00360, 09952-06010), 09950-70010 (09951-07100)

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





3. 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.





4. 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.
5. 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 over-expand the ring.





d. Coat the ring with power steering fluid.
e. Install the teflon ring to the steering rack, and settle it down with your fingers.
6. 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 teflon ring.

b. Expand 4 new teflon rings with your fingers.

NOTICE: Be careful not to over-expand 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 the teflon ring fits to the steering rack.
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. 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)
3. INSTALL STEERING RACK





a. Install SST to the steering rack.
SST 09631-20102

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

b. Coat the 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





a. Install SST to the steering rack opposite end.
SST 09631-20102
b. Coat SST with power steering fluid.
c. Coat a new oil seal lip with power steering fluid.
d. Install the oil seal by pushing it onto the SST without tilting.

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

e. Remove the SST.
SST 09631-20102
5. INSTALL SPACER AND CYLINDER END STOPPER





a. Using SST and a hammer, drive in the spacer.
SST 09950-60010 (09951-00280, 09951-00420, 09952-06010), 09950-70010 (09951-07200)





b. Coat a new O-ring with power steering fluid, and install it to the cylinder end stopper.
c. 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.





d. Using SST, torque the cylinder end stopper.
SST 09631-20120
Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.)
6. AIR TIGHTNESS TEST





a. Install the SST to the unions of 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 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.

d. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.





e. 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.





f. Using a punch, stake the bearing guide nut.
8. 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 control valve housing and rack housing, and install the control valve housing with the control valve assembly to the rack housing.
c. Install the 2 bolts.
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)
9. INSTALL DUST COVER
10. INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
a. 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
b. Temporarily install the rack guide spring cap.
11. 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. Torque the rack guide spring cap.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
c. Return the 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 rack guide spring cap until the rack guide spring is not functioning.





f. Using SST and a torque wrench, tighten the 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.)

12. 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. Holding the rack guide spring cap rotating, and using SST, torque the 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).

c. Recheck the total preload.
Preload (turning): 0.5 - 1.7 Nm (4.7 - 17.2 kgf-cm, 4.1 - 14.9 inch lbs.)
d. Remove the RH and LH rack ends.
13. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS





a. Install a new claw washer, and temporarily tighten 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 (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).





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

NOTICE: Avoid any impact to the rack.

d. Employ the same manner described above to the other side.
14. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS





a. Ensure that the steering rack hole is not clogged with grease.

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





b. Install the rack boot, clip and a new clamp.

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

c. Using pliers tighten a new clamp, as shown in the illustration.
d. Employ the same manner described above to the other side.
15. 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 lock nut.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
c. Employ the same manner described above to the other side.
16. INSTALL 2 TURN PRESSURE TUBES
a. Install 2 new union seats to the rack housing.





b. Using SST, install the 2 turn pressure tubes.
SST 09023-38201
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 value is effective in case that SST is parallel to a torque wrench.