Steering Gear: Service and Repair

RACK & PINION POWER STEERING GEAR ASSEMBLY
OVERHAUL

NOTICE:
- Remove the steering wheel assembly before the rack & pinion power steering gear assembly removal, because there is a possibility of breaking of the spiral cable.
- When installing, apply power steering fluid or molybdenum disulfide lithium base grease to the parts indicated by arrows.

1. PRECAUTION (See Restraint Systems; Service Precautions.)
2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3. DISCONNECT BATTERY NEGATIVE TERMINAL
4. REMOVE STEERING WHEEL COVER LOWER NO.2
5. REMOVE SWITCH & VOLUME CASE
6. REMOVE HORN BUTTON ASSEMBLY
7. REMOVE STEERING WHEEL ASSEMBLY
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
8. REMOVE FRONT WHEELS
9. REMOVE ENGINE UNDER COVER NO.1
a. Remove the 9 bolts, 6 screws, 2 clips and engine under cover No. 1.





10. SEPARATE TIE ROD ASSEMBLY LH
a. Remove the clip and nut from the tie rod assembly LH.
b. Using SST, separate the tie rod assembly LH from the lower ball joint assembly.
SST 09610-20012
11. SEPARATE TIE ROD ASSEMBLY RH
SST 09610-20012

HINT: Perform the same procedures as for the LH.





12. SEPARATE STEERING SLIDING W/SHAFT YOKE SUB-ASSEMBLY
a. Put matchmarks on the sliding w/shaft yoke and intermediate shaft.
b. Loosen bolt A.
c. Remove bolt B and the sliding w/shaft yoke.
13. DISCONNECT PRESSURE FEED TUBE ASSEMBLY
a. Remove the union bolt and gasket, and disconnect the pressure feed tube.
14. DISCONNECT RETURN TUBE SUB-ASSEMBLY NO.2
a. Remove the union bolt and 2 gaskets, and disconnect the return tube sub-assembly No.2.
15. REMOVE RACK& PINION POWER STEERING GEAR ASSEMBLY
a. Disconnect the PPS solenoid connector.
b. Remove the 2 nuts and power steering gear assembly.

NOTICE: Do not damage the left and right turn pressure tubes.





16. REMOVE STEERING INTERMEDIATE SHAFT
a. Put matchmarks on the intermediate shaft and control valve shaft.
b. Remove the bolt and intermediate shaft from the control valve shaft.





17. REMOVE STEERING LEFT TURN PRESSURE TUBE
a. Using SST, remove the left turn pressure tube.
SST 09023-38200
b. Remove the tube clamp.
c. Remove the union bolt and 2 gaskets, and disconnect the left turn pressure tube from the control valve housing.
18. REMOVE STEERING RIGHT TURN PRESSURE TUBE
a. Remove the 2 union bolts, 4 gaskets and right turn pressure tube.





19. FIX RACK & PINION POWER STEERING GEAR ASSEMBLY
a. Using SST, secure the power steering gear assembly in a vise.
SST 09612-00012

HINT: Wrap the SST with vinyl tape before use, in order to prevent damaging the power steering gear assembly.





20. REMOVE PRESSURE CONTROL VALVE
a. Using a hexagon wrench (6 mm), remove the 3 bolts and pressure control valve.
b. Remove the 4 O-rings from the pressure control valve.





21. REMOVE TIE ROD ASSEMBLY LH
a. Put matchmarks on the tie rod assembly LH and rack end.
b. Loosen the lock nut and remove the tie rod assembly LH and lock nut.
22. REMOVE TIE ROD ASSEMBLY RH

HINT: Perform the same procedures as for the LH.

23. REMOVE STEERING RACK BOOT NO.2
a. Using needle nose pliers, loosen the wire.
b. Remove the clip and steering rack boot No.2.

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

HINT: Mark the rack boot No. 1 to distinguish No. 1 from No.2.

24. REMOVE STEERING RACK BOOT NO.1

HINT: Perform the same procedures as for the steering rack boot No.2.

25. REMOVE STEERING RACK END SUB-ASSEMBLY





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

NOTICE: Avoid any impact to the steering rack.





b. Using a wrench, hold the steering rack securely 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 rack end to distinguish between the RH and LH sides.

c. Remove the claw washer.

d. Use the same manner described above on the other side.





26. REMOVE STEERING 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 a hexagon wrench (24 mm), remove the rack guide spring cap from the rack housing.
c. Remove the rack guide spring from the rack housing.
d. Remove the steering rack guide from the rack housing.
e. Remove the O-ring from the rack guide.
27. REMOVE POWER STEERING CONTROL VALVE





a. Using a socket wrench (27 mm), remove the rack housing cap from the rack housing.
b. Using SST, keep the control valve shaft from rotating and remove the self-locking nut.
SST 09616-00011
c. Remove the dust cover.
d. Using a hexagon wrench (6 mm), remove the 2 bolts from the control valve housing.
e. Pull out the control valve housing with the power steering control valve.
f. Remove the O-ring from the control valve housing.





g. To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve shaft.
h. Using a plastic hammer, tap out the power steering control valve.





i. Using a screwdriver, remove the 4 teflon rings from the power steering control valve.

NOTICE: Be careful not to damage the ring grooves.





j. Using a screwdriver, remove the 2 teflon rings and 2 O-rings from the power steering control valve.

NOTICE: Be careful not to damage the ring grooves.





28. REMOVE POWER STEERING CONTROL VALVE UPPER BEARING
a. Using SST and a press, press out the oil seal and upper bearing from the control valve housing.
SST 09950-60010 (09951-00240), 09950-70010 (09951-07100)
29. REMOVE POWER STEERING CONTROL VALVE LOWER BEARING
a. Remove the lower bearing from the rack housing.
30. REMOVE POWER STEERING CONTROL VALVE SPACER
a. Remove the spacer from the rack housing.





31. REMOVE POWER STEERING RACK
a. Using snap ring pliers, remove the snap ring from the rack housing.
b. Using a brass bar and a press, press the steering rack until the cylinder end stopper slightly touches the press block.
c. Pull out the steering rack with the cylinder end stopper and oil seal.

HINT: If necessary, slightly tap the rack end with a brass bar and a hammer.

32. REMOVE CYLINDER END STOPPER
a. Remove the cylinder end stopper from the steering rack.
33. REMOVE CYLINDER END STOPPER OIL SEAL
a. Remove the oil seal from the steering rack.





34. INSPECT POWER STEERING RACK
a. Using a dial indicator, check for runout of the steering rack and teeth wear.
Maximum runout: 0.3 mm (0.0118 inch)
If runout exceeds the maximum, replace the rack & pinion power steering gear assembly.
b. Check the rack surface for wear and damage.
If the steering rack is worn or damaged, replace the rack & pinion power steering gear assembly.





35. 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 to 4 seconds per turn and take the torque reading on the 5th turn.
Turning torque: 0.49 to 3.43 Nm (5.0 to 35.0 kgf-cm, 4.3 to 30.4 inch lbs.)
36. INSPECT TIE ROD ASSEMBLY RH

HINT: Perform the same procedures as for the LH.





37. REMOVE POWER STEERING RACK HOUSING OIL SEAL
a. Using SST and a press, press out the oil seal.
SST 09950-60010 (09951-00310), 09950-70010 (09951-07360)





38. REMOVE POWER STEERING CONTROL VALVE CENTER BEARING
a. Using SST, remove the center bearing from the rack housing.
SST 09612-30012

NOTICE: Be careful not to damage the rack housing.





39. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL
a. Using SST and a press, remove the oil seal from the rack housing.
SST 09612-30012

NOTICE: Be careful not to damage the rack housing.

HINT: When using SST, fit the tips of the SST into the cutouts in the rack housing.





40. REMOVE RACK STEERING PISTON RING
a. Using a screwdriver, remove the teflon ring and O-ring from the steering rack.

NOTICE: Be careful not to overexpand the teflon ring.

41. INSTALL RACK STEERING PISTON RING





a. Coat a new O-ring with power steering fluid and install it to the steering rack.
b. Expand a new teflon ring with your fingers.

NOTICE: Be careful not to overexpand the teflon ring.





c. Coat the teflon ring with power steering fluid.
d. Install the teflon ring to the steering rack and adjust with your fingers.





42. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST and a press, press in the oil seal.

SST 09950-60010 (09951-00280, 09951-00400, 09952-06010), 09950-70010 (09951-07100)

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





43. INSTALL POWER STEERING CONTROL VALVE CENTER BEARING
a. Using SST and a press, press in the center bearing.
SST 09950-60010 (09951-00460), 09950-70010 (09951-07100)





44. INSTALL POWER STEERING RACK HOUSING OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST and a press, press in the oil seal.
SST 09950-60010 (09951-00240, 09951-00430, 09952-06010), 09950-70010 (09951-07360)

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





45. INSTALL POWER STEERING RACK
a. Install SST to the steering rack.
SST 09631-20102

HINT: If necessary, scrape the burrs off the 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





46. INSTALL CYLINDER END STOPPER OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. To prevent oil seal lip damage, wind vinyl tape around the steering rack end, and apply power steering fluid.
c. Install the oil seal by pushing it into the rack housing without tilting.

NOTICE:
^ Make sure that the oil seal is installed in the correct direction.
^ Be careful not to damage the oil seal lip.





47. INSTALL CYLINDER END STOPPER
a. Using SST and a hammer, drive in the cylinder end stop per.
SST 09612-22011
b. Using snap ring pliers, install the snap ring to the rack housing.
48. AIRTIGHTNESS TEST





a. Connect the 2 SST as shown in the illustration.
SST 09631-12071, 09631-22030





b. Install SST to the rack housing.
c. Using the hand-held vacuum pump, apply 53 kPa (400 mmHg, 15.75 inch Hg) of vacuum for approximately 30 seconds.
d. Check that there is no change in the vacuum pressure.
If there is a change in the vacuum pressure, check the installation of the oil seals.





49. INSTALL POWER STEERING CONTROL VALVE OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST and a press, press in the oil seal.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07200)

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





50. INSTALL POWER STEERING CONTROL VALVE UPPER BEARING
a. Using SST and a press, press in the upper bearing.
SST 09950-60010 (09951-00340), 09950-70010 (09951-07200)
51. INSTALL POWER STEERING CONTROL VALVE
a. Expand 4 new teflon rings with your fingers.

NOTICE: Be careful not to overexpand the teflon rings.

b. Coat the 4 teflon rings with power steering fluid.
c. Install the 4 teflon rings to the power steering control valve, and adjust with your fingers.





d. Carefully slide the tapered end of SST over the teflon rings until they fit to the power steering control valve.
SST 09631-32020

NOTICE: Be careful not to damage the teflon rings.

e. Coat 2 new O-rings with power steering fluid and install them to the power steering control valve.
f. Expand 2 new teflon rings with your fingers.

NOTICE: Be careful not to overexpand the teflon rings.

g. Coat the teflon rings with power steering fluid.
h. Install the 2 teflon rings to the power steering control valve, and adjust with your fingers.





i. Carefully slide the tapered end of SST over the rings until they fit to the power steering control valve.
SST 09631-32020

NOTICE: Be careful not to damage the rings.

j. Coat the teflon rings of the power steering control valve with power steering fluid.
k. To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve shaft.
l. Install the power steering control valve into the control valve housing.

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

m. Coat a new O-ring with power steering fluid and install it to the control valve housing.





n. Using a hexagon wrench (6 mm), install the control valve housing with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
o. Install the dust cover.
p. Instal the lower bearing to the rack housing.
q. Install the spacer to the rack housing.





r. Using SST, keep the control valve shaft from rotating and install a new self-locking nut.
Torque: 59 Nm (600 kgf-cm, 44 ft. lbs.)
s. Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
t. Install the rack housing cap.
Torque: 69 Nm (705 kgf-cm, 51 ft. lbs.)
52. INSTALL STEERING RACK GUIDE
a. Coat a new O-ring with power steering fluid and install it to the steering rack guide
b. Apply grease to the rack guide spring and contact surface of the steering rack guide.
c. Install the rack guide to the steering rack housing.
d. Install the rack guide spring.
e. 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
f. Temporarily install the rack guide spring cap.
53. 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 (255 kgf-cm, 18 ft. lbs.)
c. Using a hexagon wrench (24 mm), loosen 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 stops functioning.





f. Using SST, a torque wrench and hexagon wrench (24 mm), tighten the rack guide spring cap until the preload is within specification.
SST 09616-00011
Preload (turning): 0.8 to 1.6 Nm (8 to 16 kgf-cm, 7 to 14 inch lbs.)
54. INSTALL STEERING RACK GUIDE SPRING CAP NUT
a. Apply sealant to 2 or 3 threads of the rack guide spring cap nut.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Temporarily install the rack guide spring cap nut.





c. Using a hexagon wrench (24 mm), hold the rack guide spring cap and using SST, torque the rack guide spring cap nut.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)

NOTICE: Using 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): 0.8 to 1.6 Nm (8 to 16 kgf-cm, 7 to 14 inch lbs.)
If preload is not within the specified, repeat step 53 and 54 until preload falls within the specified range.
e. Remove the RH and LH rack ends.





55. INSTALL STEERING RACK END SUB-ASSEMBLY
a. Install a new claw washer, and temporarily install the rack end.

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

b. Using a wrench, hold the steering rack securely and using SST, torque the rack end.
SST 09922-10010
Torque: 95 Nm (970 kgf-cm, 70 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 hammer, stake the washer.

NOTICE: Avoid any impact to the steering rack.

d. Use the same manner described above on the other side.





56. INSPECT POWER STEERING RACK
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.

57. INSTALL STEERING RACK BOOT NO.2





a. Install the steering rack boot No.2 with the clip and clamp.

NOTICE: Be careful not to damage or twist the steering rack boot No.2.

b. After winding and tightening the wire around the circumference of the boot twice, twist it several times, and install it.





c. As shown in the illustration, bend the wire to the circular direction to prevent damage to the steering rack boot No.2.
58. INSTALL STEERING RACK BOOT NO.1

HINT: Perform the same procedure as for the steering rack boot No.2.





59. INSTALL TIE ROD ASSEMBLY LH
a. Screw the lock nut and tie rod assembly LH 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.)
60. INSTALL TIE ROD ASSEMBLY RH

HINT: Perform the same procedures as for the LH.





61. INSTALL PRESSURE CONTROL VALVE
a. Coat 4 new O-rings with power steering fluid and install them to the pressure control valve.
b. Using a hexagon wrench (6 mm), install the pressure control valve with the 3 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





62. INSTALL STEERING LEFT TURN PRESSURE TUBE
a. Using SST, connect the left turn pressure tube.
SST 09023-38200
Torque: 23 Nm (235 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 when SST is parallel to the torque wrench.

b. Install the left turn pressure tube and 2 new gaskets with the union bolt.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
c. Install the tube clamp.
63. INSTALL STEERING RIGHT TURN PRESSURE TUBE
a. Install the right turn pressure tube and 4 new gaskets with the 2 union bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)





64. CONNECT STEERING INTERMEDIATE SHAFT
a. Align the matchmarks on the intermediate shaft and control valve shaft.
b. Install the bolt.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)
65. INSTALL RACK& PINION POWER STEERING GEAR ASSEMBLY
a. Install the power steering gear assembly with the 2 nuts.
Torque: 118 Nm (1,205 kgf-cm, 87 ft. lbs.)

NOTICE: Do not damage the turn pressure tubes.

b. Connect the PPS solenoid connector.
66. CONNECT RETURN TUBE SUB-ASSEMBLY NO.2
a. Install 2 new gaskets on each side of the return tube and connect the return tube with the union bolt.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
67. CONNECT PRESSURE FEED TUBE ASSEMBLY
a. Install a new gasket, then connect the pressure feed tube with the union bolt.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





68. CONNECT STEERING SLIDING W/SHAFT YOKE SUB-ASSEMBLY
a. Align the matchmarks on the sliding w/shaft yoke and control valve shaft.
b. Install the 2 bolts.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)
69. CONNECT TIE ROD ASSEMBLY LH
a. Install the tie rod assembly LH to the lower ball joint assembly with the nut.
Torque: 59 Nm (600 kgf-cm, 44 ft. lbs.)
b. Install the clip.
70. CONNECT TIE ROD ASSEMBLY RH

HINT: Perform the same procedures as for the LH.

71. INSTALL ENGINE UNDER COVER NO.1
a. Install the engine under cover No.1 with the 9 bolts, 6 screws and 2 clips.
72. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
73. INSPECT CENTER FRONT WHEEL

HINT: Inspect with the front of the vehicle jacked up.

74. CENTER SPIRAL CABLE
75. INSTALL STEERING WHEEL ASSEMBLY
a. Align the matchmarks on the steering wheel assembly and main shaft assembly.
b. Temporarily tighten the steering wheel assembly set nut.
c. Connect the connector.
76. CONNECT BATTERY NEGATIVE TERMINAL
77. BLEED AIR IN POWER STEERING SYSTEM
78. CHECK FOR POWER STEERING FLUID LEAKAGE
If any leakage is found on the power steering system, repair or replace the related parts.
79. INSPECT STEERING WHEEL CENTER POINT
80. FULLY TIGHTEN STEERING WHEEL ASSEMBLY
a. Tighten the steering wheel assembly set nut.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
81. INSTALL HORN BUTTON ASSEMBLY
82. INSTALL SWITCH & VOLUME CASE
83. INSTALL STEERING WHEEL COVER LOWER NO.2
84. CHECK POWER STEERING FLUID LEVEL IN RESERVOIR
85. PERFORM INITIALIZATION
86. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
87. CLEAR ZERO POINT CALIBRATION FOR VSC
88. PERFORM ZERO POINT CALIBRATION OF YAW RATE SENSOR AND DECELERATION SENSOR
89. INSPECT ABS WARNING LIGHT AND VSC WARNING LIGHT
90. INSPECT SRS WARNING LIGHT