Steering Gear: Service and Repair

STEERING GEAR (for 4WD)

Components:

REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. SEPARATE CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER
5. SEPARATE NO.2 STEERING INTERMEDIATE SHAFT ASSEMBLY

a) Fix the steering wheel with the seat belt in order to prevent rotation.

HINT: This operation is useful to prevent damage to the spiral cable.

b) Remove the bolt and slide the No.2 steering intermediate shaft assembly.

HINT: Do not separate the No.2 steering intermediate shaft assembly from the power steering gear assembly.

c) Put matchmarks on the No.2 steering intermediate shaft assembly and the power steering gear assembly.
d) Separate the No.2 steering intermediate shaft assembly from the power steering gear assembly.

6. SEPARATE TIE ROD ASSEMBLY LH
a) Remove the clip and the nut.

b) Using SST, separate the tie rod assembly LH from the steering knuckle.
SST 09628-00011

NOTICE:
^ Hang SST with a string, etc. to prevent it from failing.
^ Do not damage the front disc brake dust cover.
^ Do not damage the ball joint dust cover.
^ Do not damage the steering knuckle.
^ Make sure that the SST is securely set to the steering knuckle spacer.
^ If the spacer has come off, replace the steering knuckle with a new one.

7. SEPARATE TIE ROD ASSEMBLY RH
SST 09628-00011

HINT: Perform the same procedure as for the LH side.

8. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION

HINT: Refer to the instructions for removal of the engine assembly (4GR-FSE).

9. REMOVE POWER STEERING GEAR ASSEMBLY

a) Remove the 2 bolts, 2 nuts, and the power steering gear assembly from the front frame assembly.

DISASSEMBLY
1. FIX POWER STEERING GEAR ASSEMBLY

a) Using SST, secure the power steering gear assembly.
SST 09612-00012

HINT: Tape the SST before use.

2. REMOVE TIE ROD ASSEMBLY LH

a) Put matchmarks on the tie rod assembly LH and the steering rack end sub-assembly.
b) Loosen the lock nut, and remove the tie rod assembly LH and the lock nut.

3. REMOVE TIE ROD ASSEMBLY RH

HINT: Perform the same procedure as for the LH side.

4. REMOVE STEERING RACK BOOT CLIP
a) Using pliers, remove the 2 steering rack boot clips.

5. REMOVE NO.1 STEERING RACK BOOT CLAMP

a) Using pliers and a screwdriver, remove the No.1 steering rack boot clamp (LH side) as shown in the illustration.

NOTICE: Be careful not to damage the boot.

b) Remove the RH side by using the same procedure as for the LH side.

6. REMOVE NO.1 STEERING RACK BOOT
a) Remove the 2 No.1 steering rack boots.

7. REMOVE STEERING RACK END SUB-ASSEMBLY

a) Using a screwdriver and a hammer, unstake the RH and LH claw washers.

NOTICE: Avoid any impact to the steering rack.

b) Using 2 SST, remove the steering rack end sub assembly (LH side) and the claw washer.
SST 09922-10010

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

c) Using 2 SST, remove the steering rack end sub assembly (RH side) and the claw washer.
SST 09922-10010

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

HINT: Using SST, hold the rack and remove the steering rack end sub-assembly.

INSPECTION
1. INSPECT TOTAL PRELOAD
a) Temporarily install the left and right steering rack ends to prevent steering rack overstroke.

b) Using SST and a torque wrench, inspect preload.
SST 09616-00011
Preload (turning): 1.0 to 2.0 Nm (10.2 to 20.4 kgf-cm, 8.9 to 17.7 inch lbs.)

HINT: If turning torque is not as specified, replace the power steering gear assembly.

2. 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 back and forth 5 times or more.

d) Using a torque wrench, turn the nut continuously at a rate of 3 to 5 seconds per turn and take the torque reading on the 5th turn.
Turning torque: 0.29 to 2.45 Nm (3.0 to 25 kgf-cm, 2.6 to 21.7 inch lbs.)

HINT: If turning torque is not within the specified range, replace the tie rod assembly LH.

3. INSPECT TIE ROD ASSEMBLY RH

HINT: Perform the same procedure as for the LH side.

REASSEMBLY

NOTICE: When installing, coat the parts indicated by arrows with lithium soap base glycol grease.

1. INSTALL STEERING RACK END SUB-ASSEMBLY
a) Install 2 new claw washers.

HINT: Align the claws of the claw washer with the steering rack grooves.

b) Using 2 SST, install the steering rack end sub assembly (RH side).
SST 09922-10010
Torque: 76 Nm (775 kgf-cm, 56 ft. lbs.)

NOTICE:
^ Use SST09922-10010 following the direction shown in the illustration.
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

HINT: Using SST, hold the steering rack and install the steering rack end sub-assembly.

c) Using 2 SST, install the steering rack end sub assembly (LH side).
SST 09922-10010
Torque: 76 Nm (775 kgf-cm, 56 ft. lbs.)

NOTICE:
^ Use SST09922-10010 following the direction shown in the illustration.
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

HINT: Using SST, hold the steering rack and install the steering rack end sub-assembly.

d) Using a brass bar and a hammer, stake the 2 claw washers.

NOTICE: Avoid any impact to the steering rack.

2. INSTALL NO.1 STEERING RACK BOOT

a) Apply lithium soap base glycol grease to the inside of the small opening of the No.1 steering rack boot (LH side).

b) Temporarily install a new No.1 steering rack boot clamp to the large opening of the No.1 steering rack boot (LH side) at the position shown by arrow (A).

NOTICE:
^ Use a new No.1 steering rack boot clamp.
^ Do not expand the No.1 steering rack boot clamp more than necessary for installation.
^ Do not deform the No.1 steering rack boot clamp.
^ Tightening force of the No.1 steering rack boot clamp becomes uneven if it is installed after being expanded as shown in the illustration. As a result, rust is caused by water entering from the clearance between the No.1 steering rack boot and rack housing, causing a malfunction.
^ Use only the supply parts which are applicable to the vehicle to secure the No.1 steering rack boot.

HINT: After disengaging the claw of a new No.1 steering rack boot clamp, temporarily install it from the end without expanding the clamp diameter more than necessary.

c) Install the No.1 steering rack boot (LH side) to the groove on the rack housing.

NOTICE:
^ Be careful not to damage or twist the No.1 steering rack boot.
^ Do not damage the No.1 steering rack boot (LH side).
^ Ensure that the No.1 steering rack boot clamp is installed before installing the No.1 steering rack boot (LH side) to the rack housing.

d) Install the RH side by using the same procedure as for the LH side.

3. INSTALL NO.1 STEERING RACK BOOT CLAMP

a) Using pliers and a screwdriver, install the No.1 steering rack boot clamp (LH side).

NOTICE:
^ Be careful not to damage the No.1 steering rack boot.
^ Do not twist the No.1 steering rack boot.

HINT: Make sure that the protrusion of the steering rack boot clamp is positioned within the area shown in the illustration.

b) Install the RH side by using the same procedure as for the LH side.

4. INSTALL STEERING RACK BOOT CLIP

a) Using pliers, install the 2 boot clips.

HINT: Make sure that the each clip claw is positioned within the area shown in the illustration.

b) Using SST, turn the pinion and check that the rack boots expand and contract smoothly.
SST 09616-00011

5. INSTALL TIE ROD ASSEMBLY LH

a) Install the lock nut and the tie rod assembly to the rack end until the matchmarks are aligned.

HINT: After adjusting toe-in, torque the lock nut.

6. INSTALL TIE ROD ASSEMBLY RH

HINT: Perform the same procedure as for the LH side.

INSTALLATION
1. INSTALL POWER STEERING GEAR ASSEMBLY

a) Install the power steering gear assembly with the 2 bolts and 2 nuts.
Torque: 102 Nm (1,038 kgf-cm, 75 ft. lbs.)

2. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION

HINT: Refer to the instructions for installation of the engine assembly (4GR-FSE).

3. CONNECT TIE ROD ASSEMBLY LH
a) Connect the tie rod assembly LH to the steering knuckle with the nut.
Torque: 65 Nm (663 kgf-cm, 48 ft. lbs.)
b) Install a new clip.

4. CONNECT TIE ROD ASSEMBLY RH

HINT: Perform the same procedure as for the LH side.

5. CONNECT NO.2 STEERING INTERMEDIATE SHAFT ASSEMBLY

a) Align the matchmarks on the No.2 steering intermediate shaft assembly and the power steering gear assembly.

b) Install the bolt.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)

6. INSTALL ENGINE UNDER COVER
7. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)

8. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
9. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
10. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
11. PERFORM INITIALIZATION

HINT: Some systems need initialization when disconnecting the cable from the negative battery terminal.

12. INITIALIZE ROTATION ANGLE SENSOR AND CALIBRATE TORQUE SENSOR ZERO POINT