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RACK & PINION POWER STEERING GEAR ASSEMBLY
OVERHAUL

NOTICE: When installing, coat the parts indicated by the arrow with power steering fluid or molybdenum disulfide lithium base grease.

1. OBSERVE RESTRAINT SYSTEMS SERVICE PRECAUTIONS
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE HORN BUTTON ASSEMBLY
4. REMOVE STEERING WHEEL ASSEMBLY
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
5. REMOVE FRONT WHEEL
6. REMOVE SPIRAL CABLE SUB-ASSEMBLY
7. DISCONNECT TIE ROD ASSEMBLY LH
a. Remove the cotter pin and nut.





b. Using SST, remove the tie rod assembly LH from the steering knuckle.
SST 09628-62011
8. DISCONNECT TIE ROD ASSEMBLY RH
SST 09628-62011

HINT: Remove the RH side by the same procedures with LH. side.

9. DISCONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY





a. Loosen the bolt and remove the clamp from the steering column hole cover No. 1.
b. Disconnect the steering column hole cover No. 2 from the steering column hole cover No. 1.
c. Loosen the bolt.





d. Place matchmarks on the steering intermediate shaft sub-assembly and rack & pinion power steering gear assembly.
e. Remove the bolt and disconnect the steering intermediate shaft sub-assembly.





10. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH
a. Remove the nut and disconnect the front stabilizer link assembly LH from the shock absorber assembly front LH.

HINT: If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.

11. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT: Remove the RH side by the same procedures with LH side.





12. REMOVE FRONT STABILIZER BRACKET NO. 1 LH
a. Remove the 2 bolts and disconnect the front stabilizer bracket No. 1 LH.
13. REMOVE FRONT STABILIZER BRACKET NO. 1 RH

HINT: Remove the RH side by the same procedures with LH side.

14. DISCONNECT PRESSURE FEED TUBE ASSEMBLY





a. Using SST, disconnect the return tube assembly from the rack & pinion power steering gear assembly.
SST 09023-12701





b. Using SST, disconnect the pressure feed tube assembly from the rack & pinion power steering gear assembly.
SST 09023-12701





c. Remove the nut and disconnect the return tube assembly clamp.
15. REMOVE RACK & PINION POWER STEERING GEAR ASSEMBLY





a. Remove the bolt and disconnect the tube clamp.





b. Remove the 2 bolts, 2 nuts and rack & pinion power steering gear assembly.
16. REMOVE POWER STEERING RACK HOUSING HEAT INSULATOR
a. Remove the power steering rack housing heat insulator.
17. REMOVE STEERING LEFT TURN PRESSURE TUBE





a. Using SST, remove the steering left turn pressure tube.
SST 09023-38201
b. Remove the 2 O-rings from the steering left turn pressure tube.
18. REMOVE STEERING RIGHT TURN PRESSURE TUBE
a. Using SST, remove the steering right turn pressure tube.
SST 09023-38201
b. Remove the 2 O-rings from the steering right turn pressure tube.
19. FIX RACK & PINION POWER STEERING GEAR ASSEMBLY





a. Using SST, secure the rack & pinion power steering gear assembly.
SST 09612-00012

HINT: Tape the SST before use.





20. REMOVE TIE ROD ASSEMBLY LH
a. Place matchmarks on the tie rod assembly LH and steering rack end sub-assembly.
b. Loosen the lock nut, and remove the tie rod assembly LH and lock nut.
21. REMOVE TIE ROD ASSEMBLY RH

HINT: Remove the RH side by the same procedures with LH side.





22. INSPECT TIE ROD ASSEMBLY LH
a. Secure the tie rod assembly 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 torque 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: 0.83 - 3.43 Nm (8.5 - 35.0 kgf-cm, 7.3 - 30.4 inch lbs.)
23. INSPECT TIE ROD ASSEMBLY RH

HINT: Remove the RH side by the same procedures with LH side.

24. REMOVE STEERING RACK BOOT CLIP
a. Remove the 2 steering rack boot clips.
25. REMOVE STEERING RACK BOOT NO. 2 CLAMP
a. Using pliers, remove the steering rack boot NO. 2 clamp.

NOTICE: Be careful not to damage the steering rack boot NO. 2.

26. REMOVE STEERING RACK BOOT NO. 1 CLAMP

HINT: Remove the steering rack boot No 1 clamp by the same procedures with the steering rack boot No 2 clamp.

NOTICE: Be careful not to damage the steering rack boot NO. 1.

27. REMOVE STEERING RACK BOOT NO. 2.
a. Remove the steering rack boot NO. 2.
28. REMOVE STEERING RACK BOOT NO. 1

HINT: Remove the steering rack boot NO. 1 by the same procedures with the steering rack boot NO. 2.

29. REMOVE STEERING RACK END SUB-ASSEMBLY





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

NOTICE: Avoid any impact to the power steering rack.





b. Using 2 SSTs, remove the 2 steering rack ends sub-assembly and 2 claw washers.
SST 09922-10010

NOTICE:
^ Use SST 09922-10010 in the direction shown in the illustration.
^ Securely hold the steering rack end sub-assembly with a SST.

30. REMOVE RACK GUIDE





a. Using SST, remove the rack guide spring cap nut.
SST 09922-10010

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





b. Using SST, remove the rack guide spring cap.
SST 09631-10021
c. Remove the compression spring and rack guide.
31. REMOVE POWER STEERING CONTROL VALVE





a. Using a socket wrench (27 mm), remove the rack housing cap





b. Using SST, hold the control valve and remove the nut.
SST 09616-00011





c. Wind vinyl tape around the serrated part of the control valve.
d. Remove the dust cover from the control valve housing.





e. Remove the 2 bolts and control valve housing.
f. Remove the gasket.





g. To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
h. Using a plastic hammer, remove the control valve with oil seal from the control valve housing.
i. Remove the oil seal from the control valve.





j. Using a screwdriver, remove the 4 control valve rings.

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

32. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL





a. Using SST and a press, remove the control valve upper bearing and power steering control valve upper oil seal from the control valve housing.
SST 09950-70010 (09951-07150), 09950-60010 (09951-00250)





33. REMOVE CYLINDER END STOPPER
a. Using a screwdriver and a hammer, turn the cylinder end stopper clockwise until the wire end is visible through the service hole.
b. Using a screwdriver and a hammer, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper.
34. REMOVE POWER STEERING RACK
a. Remove the power steering rack and power steering rack bush.
35. REMOVE POWER STEERING RACK BUSH
a. Remove the power steering rack bush from the power steering rack.





b. Using SST, remove the rack bush oil seal.
SST 09527-21011, 09612-24014 (09613-22011)
c. Using a screwdriver, remove the O-ring from the power steering rack bush.





36. INSPECT POWER STEERING RACK
a. Using a dial indicator, check the power steering rack for runout and for teeth wear and damage.
Maximum runout: 0.3 mm (0.012 inch)
b. Check the back surface for wear and damage.
37. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL





a. Using SST and a press, remove the power steering cylinder tube oil seal.
SST 09950-70010 (09951-07360), 09950-60010 (09951-00290)





38. REMOVE RACK STEERING PISTON RING
a. Using a screwdriver, remove the rack steering piston ring and O-ring.

NOTICE: Be careful not to damage the grooves for rack steering piston ring.

39. INSTALL RACK STEERING PISTON RING
a. Coat a new O-ring with power steering fluid and install it to the power steering rack.





b. Expand a new rack steering piston ring with your fingers.

NOTICE: Be careful not to over expand the rack steering piston ring.

c. Coat the new rack steering piston ring with power steering fluid.





d. Install the rack steering piston ring to the power steering rack, and settle it down with your fingers.
40. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL





a. Coat a new power steering cylinder tube oil seal lip with power steering fluid.
SST 09950-60010 (09951-00420, 09951-00250, 09952-06010), 09950-70010 (09951-07360)
b. Using SST and a press, install the power steering cylinder tube oil seal.

NOTICE:
^ Make sure that the power steering cylinder tube oil seal is installed facing in the correct direction.
^ Take care so that the power steering cylinder tube oil seal will not be reversed as you install it.

41. INSTALL POWER STEERING RACK





a. Install SST to the power steering rack.
SST 09631-33010

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

b. Coat the SST with power steering fluid.
c. Install the power steering rack into the rack housing.
d. Remove the SST.
42. INSTALL POWER STEERING RACK BUSH





a. Using SST and a press, install the rack bush oil seal to the power steering rack bush.
SST 09950-60010 (09951-00400), 09950-70010 (09951-07100)

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

b. Coat a new O-ring with power steering fluid and install it to the power steering rack bush.





c. To prevent rack bush oil seal lip damage, wind vinyl tape around the power steering rack end, and apply power steering fluid.
d. Install the power steering rack bush to the power steering rack.





43. INSTALL CYLINDER END STOPPER
a. Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing.
b. Install a new wire into the cylinder end stopper.
c. Using a screwdriver, turn the cylinder end stopper clockwise by 450 ± 50°.





44. AIR TIGHTNESS TEST
a. Install SST to the rack housing.
SST 09631-12071 (09633-00010)
b. Apply vacuum of 53 kPa (400 mm Hg, 15.75 inch Hg) 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.