Part 1

POWER STEERING LINK

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE FRONT WHEELS

4. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY
(a) Secure 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 steering intermediate shaft assembly.

NOTICE: Do not separate the steering intermediate shaft assembly from the power steering link assembly.

(c) Put matchmarks on the steering intermediate shaft assembly and the power steering link assembly.
(d) Separate the steering intermediate shaft assembly from the power steering link assembly.

5. SEPARATE TIE ROD ASSEMBLY LH
(a) Remove the cotter pin 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 falling.
^ Do not damage the front disc brake dust cover.
^ Do not damage the ball joint dust cover.
^ Do not damage the steering knuckle.

6. SEPARATE TIE ROD ASSEMBLY RH

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

7. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

HINT: Refer to the instructions for REMOVAL of the ENGINE ASSEMBLY.

8. DISCONNECT PRESSURE FEED TUBE ASSEMBLY
(a) Using SST, disconnect the pressure feed tube assembly (return tube side) from the power steering link assembly.
SST 09023-12701

(b) Using SST, disconnect the pressure feed tube assembly (pressure feed tube side) from the power steering link assembly.
SST 09023-12701

9. REMOVE POWER STEERING LINK ASSEMBLY
(a) Remove the 2 bolts, 2 nuts, and the power steering link assembly.

NOTICE: Because the nut has its own stopper, do not turn the nut. Loosen the bolt with the nut fixed.

10. REMOVE POWER STEERING RACK HOUSING HEAT INSULATOR
(a) Remove the power steering rack housing heat insulator from the power steering link assembly.

DISASSEMBLY

1. SECURE POWER STEERING LINK ASSEMBLY
(a) Using SST, secure the power steering link assembly.
SST 09612-00012

HINT: Tape the SST before use.

2. 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.

3. 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.

4. 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.

5. REMOVE TIE ROD ASSEMBLY RH

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

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

7. REMOVE NO. 2 STEERING RACK BOOT CLAMP
(a) Using pliers, remove the 2 No. 2 steering rack boot clamps as shown in the illustration.

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

8. REMOVE NO. 2 STEERING RACK BOOT
(a) Remove the No. 2 steering rack boot.

9. REMOVE NO. 1 STEERING RACK BOOT
(a) Remove the No. 1 steering rack boot.

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

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

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

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

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

11. REMOVE RACK GUIDE
(a) Using a straight hexagon wrench (24 mm (0.94 in.)), remove the rack guide spring cap.

(b) Remove the compression spring and the rack guide sub-assembly.

(d) Remove the O-ring from the rack guide spring cap.

12. REMOVE DUST COVER
(a) Wrap protective tape around the spline of the control valve in order to prevent damaging the dust cover.
(b) Remove the dust cover.

13. REMOVE POWER STEERING CONTROL VALVE ASSEMBLY
(a) Using a socket wrench (27 mm (1.06 in.)), remove the rack housing cap.

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

14. REMOVE POWER STEERING CONTROL VALVE SUB-ASSEMBLY
(a) Using a press, remove the power steering control valve sub-assembly.

15. REMOVE POWER STEERING CONTROL VALVE LOWER OIL SEAL
(a) Remove the power steering control valve lower oil seal from the power steering control valve sub-assembly.

16. REMOVE POWER STEERING CONTROL VALVE SPACER
(a) Using a screwdriver, remove the 4 power steering control valve spacers from the power steering control valve sub-assembly.

NOTICE: Be careful not to damage the spacer grooves on the control valve.

HINT: Tape the screwdriver tip before use.

17. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL
(a) Using SST and a press, press out the power steering control valve upper oil seal and the power steering control valve upper bearing from the control valve housing sub-assembly.
SST 09950-70010 (09951-07150), 09950-60010 (09951-00250, 09951-00180, 09952-06010)

18. REMOVE CYLINDER END STOPPER HOLE SNAP RING
(a) Using needle-nose pliers, remove the cylinder end stopper hole snap ring from the power steering rack housing.

19. REMOVE POWER STEERING RACK SUB-ASSEMBLY
(a) Remove the power steering rack sub-assembly with the cylinder end stopper and power steering rack bushing.

20. REMOVE CYLINDER END STOPPER
(a) Remove the cylinder end stopper from the power steering rack sub-assembly.

21. REMOVE POWER STEERING RACK BUSHING
(a) Remove the power steering rack bushing from the power steering rack sub-assembly.

(b) Using a screwdriver, remove the O-ring from the power steering rack bushing.

HINT: Tape the screwdriver tip before use.

(c) Using SST, remove the rack bushing oil seal from the power steering rack bushing.
SST 09527-21011, 09612-24014 (09613-22011)

NOTICE: Be careful not to drop the power steering rack bushing.

22. 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, 09951-00250)

NOTICE: Be careful not to damage the inside surface of the power steering rack housing.

23. REMOVE POWER PISTON OIL SEAL
(a) Using a screwdriver, remove the power piston oil seal and the O-ring from the power steering rack.

NOTICE: Be careful not to damage the power piston oil seal groove on the power steering rack.

HINT: Tape the screwdriver tip before use.

INSPECTION

1. INSPECT POWER STEERING RACK
(a) Using a dial indicator, check for teeth wear and runout of the steering rack.
Maximum runout: 0.3 mm (0.0118 in.)

NOTICE: Make sure that the steering rack is placed horizontally.

If runout exceeds the maximum, replace the power steering link assembly.

(b) Check the rack surface for wear and damage.

2. INSPECT TIE ROD ASSEMBLY LH
(a) Secure the tie rod end 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.
Torque: Turning torque 0.98 to 3.92 N*m (10 to 40 kgf*cm, 8.7 to 34.7 in.*lbf)

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.

4. INSPECT TOTAL PRELOAD
(a) Temporarily install the 2 steering rack ends to the power steering rack.

NOTICE: Do not fully turn the power steering rack without the steering rack ends as it may damage the oil seal in the rack housing.

(b) Using SST, fully turn the power steering rack right and left 10 times to settle it.
SST 09616-00011

(c) Using SST, turn the control valve and measure the preload.
SST 09616-00011
Torque: Standard preload (turning) 1.5 N*m (15.3 kgf*cm, 13.3 in.*lbf) or less

If the preload exceeds the specified value, go back to INSTALL RACK GUIDE.

(d) Remove the 2 steering rack ends from the power steering rack.

REASSEMBLY

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

1. INSTALL POWER PISTON OIL SEAL
(a) Coat a new O-ring with power steering fluid and install it to the steering rack.

(b) Expand the new power piston oil seal with your fingers.

NOTICE: Be careful not to expand the oil seal excessively.

(c) Coat the power piston oil seal with power steering fluid.

(d) Install the power piston oil seal to the steering rack, and adjust it with your fingers.

2. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL
(a) Apply power steering fluid to the lip of a new power steering cylinder tube oil seal.
(b) Install the power steering cylinder tube oil seal to the rack housing at a slant.

(c) Using SST, insert the power steering cylinder tube oil seal by pushing the SST in by hand until the oil seal passes the 2 ports.
SST 09950-70010 (09951-07360), 09631-00200

NOTICE:
^ Ensure that the power steering cylinder tube oil seal is installed in the correct direction as shown in the illustration.
^ Install the power steering cylinder tube oil seal at an angle of approximately 15° so that the lowermost part comes to the point, indicated by the arrow in the illustration, to prevent damage to the side of the oil seal when it passes the 2 ports.
^ Do not turn the SST when inserting the oil seal.

(d) Install SST (09631-00200) to SST (09951-07360) upside down.

(e) Using SST, level the power steering cylinder tube oil seal by pushing the SST in by hand. Using SST and a press, install the oil seal.
SST 09950-70010 (09951-07360), 09631-00200

3. INSTALL POWER STEERING RACK SUB-ASSEMBLY
(a) Apply molybdenum disulfide lithium base grease to the rack teeth ends.

(b) Connect SST to the power steering rack sub-assembly.
SST 09631-33010
(c) Coat SST with power steering fluid.
(d) Install the power steering rack sub-assembly to the power steering rack housing.
(e) Remove SST.

4. INSTALL POWER STEERING RACK BUSHING
(a) Using SST and a press, install the rack bushing oil seal to the power steering rack bushing.
SST 09950-70010 (09951-07100), 09950-60010 (09951-00400, 09951-00250, 09952-06010)

NOTICE: Ensure that the rack bushing oil seal is installed in the correct direction as shown in the illustration.

(b) Coat a new O-ring with power steering fluid and install it to the rack bushing.
(c) Coat the rack bushing oil seal lip with power steering fluid.

(d) Install the power steering rack bushing to the power steering rack housing.

NOTICE: Do not damage the rack bushing oil seal.

HINT: Wrap protective tape around the end of the steering rack in order to prevent damage to the rack bushing oil seal.

5. INSTALL CYLINDER END STOPPER
(a) Install the cylinder end stopper to the power steering rack housing.

6. INSTALL CYLINDER END STOPPER HOLE SNAP RING
(a) Using needle nose pliers, install the cylinder end stopper hole snap ring to the power steering rack housing.

NOTICE:
^ Make sure that the cylinder end stopper hole snap ring is securely installed in the power steering rack housing groove.
^ Make sure that the cylinder end stopper hole snap ring claws are aligned with the cylinder end stopper notch.