Part 1

RACK AND PINION POWER STEERING GEAR

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

REMOVAL

NOTICE: Do not remove the steering wheel before removing the rack and pinion power steering gear. There is a possibility that the spiral cable may break.

1. PRECAUTION
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE FRONT WHEELS
(a) Remove the 20 bolts and ornaments.
(b) Remove the 10 nuts and front wheels.
5. REMOVE SWITCH AND VOLUME CASE
6. REMOVE STEERING PAD SWITCH MODULATOR
7. REMOVE NO. 2 STEERING WHEEL COVER LOWER
8. REMOVE STEERING PAD ASSEMBLY
9. REMOVE STEERING WHEEL ASSEMBLY
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

10. DISCONNECT TIE ROD ASSEMBLY LH
(a) Remove the 2 bolts and caliper.
(b) Support the brake caliper securely.
(c) Remove the clip and nut.

(d) Using SST, disconnect the tie rod end from the lower ball joint.
11. DISCONNECT TIE ROD ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

12. REMOVE NO. 2 ENGINE UNDER COVER

13. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH
(a) Remove the bolt, nut and brace.

14. REMOVE FRONT SUSPENSION MEMBER BRACE REAR LH
(a) Remove the bolt, nut and brace.

15. REMOVE FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY
(a) Remove the 4 bolts and brace.

16. DISCONNECT STEERING SLIDING YOKE SUB-ASSEMBLY
(a) Place matchmarks on the steering sliding yoke and control valve shaft.
(b) Loosen the bolt labeled A, remove the bolt labeled B and disconnect the steering sliding yoke.

17. DISCONNECT PRESSURE FEED TUBE ASSEMBLY
(a) Pressure feed tube:
Remove the union bolt and gasket.
(b) Return tube:
Remove the union bolt and 2 gaskets.

HINT: When the tool cannot be easily inserted, loosen the 4 rack and pinion power steering gear set bolts. Then slide the rack and pinion power steering gear rearward slightly.

18. REMOVE RACK AND PINION POWER STEERING GEAR ASSEMBLY
(a) Remove the 2 bolts and disconnect the 2 tube clamps.
(b) Disconnect the connector.
(c) Remove the 4 gear set bolts and rack and pinion power steering gear.
(d) Remove the No. 2 steering rack housing bracket and grommet.

DISASSEMBLY

1. FIX RACK AND PINION POWER STEERING GEAR ASSEMBLY
(a) Using SST, remove the steering right turn pressure tube and steering left turn pressure tube.
SST 09023-38200
(b) Remove the steering turn pressure tube union seat from the power steering rack housing.

2. REMOVE TIE ROD ASSEMBLY LH
(a) Place matchmarks on the tie rod LH and rack end.
(b) Loosen the lock nut, and remove the tie rod LH lock nut.
3. REMOVE TIE ROD ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

4. REMOVE STEERING RACK BOOT CLIP
(a) Remove the 2 boot clips.

5. REMOVE NO. 1 STEERING RACK BOOT CLAMP
(a) Using pliers, loosen the clamp as shown in the illustration.

NOTICE: Be careful not to damage the steering rack boot.

6. REMOVE NO. 2 STEERING RACK BOOT CLAMP

HINT: Use the same procedures described for the No. 1 boot clamp.

7. REMOVE NO. 1 STEERING RACK BOOT
(a) Remove the clip and rack boot.

HINT: Mark the No. 1 and No. 2 rack boots.

8. REMOVE NO. 2 STEERING RACK BOOT

HINT: Use the same procedures described for the No. 1 steering rack boot.

9. REMOVE STEERING RACK END SUB-ASSEMBLY
(a) Using a screwdriver and hammer, unstake the washer.

NOTICE: Avoid any impact to the steering rack.

(b) Using a wrench, hold the steering rack steadily. Using SST, remove the rack end.
SST 09922-10010

NOTICE: Rotate SST in the direction shown in the illustration.

(c) Use the same procedure described for the other side.

HINT: Mark the RH and LH rack ends.

10. REMOVE STEERING RACK END CLAW WASHER
(a) Remove the 2 steering rack end claw washers.

11. REMOVE STEERING RACK GUIDE
(a) Using SST, remove the cap nut.
SST 09922-10010

NOTICE: Rotate SST as shown in the illustration.

(b) Remove the spring cap, rack guide spring, conical spring washer and rack guide.
(c) Remove the rack guide seat from the rack guide.

12. REMOVE POWER STEERING CONTROL VALVE
(a) Remove the steering gear dust cover.
(b) Place the matchmarks on the control valve housing and rack housing.
(c) Remove the 2 bolts.
(d) Pull out the control valve with the control valve housing.
(e) Remove the O-ring from the rack housing.

(f) Using SST, loosen the bearing guide nut.
SST 09631-20060

(g) Wind vinyl tape around the control valve shaft.
(h) Using a plastic-faced hammer, tap out the control valve (with bearing guide nut) from the control valve housing.

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

(i) Remove the bearing guide nut from the power steering control valve.

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

(j) Remove the O-ring from the bearing guide nut.

(k) Using a screwdriver, remove the 4 control valve rings from the control valve.

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

13. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL
(a) Using SST, press out the oil seal and bearing from the control valve housing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07150)

14. REMOVE POWER STEERING CONTROL VALVE LOWER OIL SEAL
(a) Using SST, press out the oil seal from the bearing guide nut.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)

15. REMOVE CYLINDER END STOPPER
(a) Using SST, remove the stopper.
SST 09631-20090
(b) Remove the O-ring from the stopper.

16. REMOVE POWER STEERING RACK
(a) Using SST, press out the steering rack, housing spacer and rack housing oil seal.

NOTICE: Take care not to drop the power steering rack.

(b) Remove the cylinder housing spacer and rack housing oil seal from the steering rack.

17. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL
(a) Install SST (09612-07130) on SST (09612-07210).
SST 09612-70100 (09612-07130, 09612-07210)

NOTICE:
^ Before using SSTs, apply a small dab of grease to the inside wall of SSTs (0961207210, 09612-07130).
^ To prevent the inside of the housing from being damaged, securely install SSTs together.

(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).

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.

HINT: Place SST on the chamfering position between the oil seal and rack housing.

(d) Remove SST (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).

NOTICE:
^ Before using SSTs, apply a small dab of grease to the tip of SSTs (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.

NOTICE: Do not damage the rack housing.

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

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

NOTICE: Be careful not to damage the groove of the oil seal.

INSPECTION

1. INSPECT TIE ROD ASSEMBLY LH
(a) Secure the tie rod 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 of the 5 the turn.
Standard turning torque: 0.49 to 3.43 N*m (5.0 to 35 kgf*cm, 4.34 to 30.38 in.*lbf)
2. INSPECT TIE ROD ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

3. INSPECT POWER STEERING CONTROL VALVE
(a) Check the bearing rotation condition and check for abnormal noise.
If the bearing is worn or damaged, replace the control valve.
(b) Coat the bearing with molybdenum disulfide lithium base grease.

4. INSPECT CYLINDER END STOPPER
(a) Check the inside of the bushing of the stopper for cracks.
If faulty, replace the bushing.
(b) Apply molybdenum disulfide lithium base grease to the inside of the bushing.

5. INSPECT POWER STEERING RACK
(a) Using a dial indicator, check for runout of the steering rack and teeth wear.
Maximum runout: 0.03 mm (0.0118 in.)
If runout exceeds the maximum, replace the rack & pinion power steering gear.
(b) Check the back surface for wear and damage. If the steering rack is worn or damaged, replace the rack & pinion power steering gear.

6. INSPECT POWER STEERING CONTROL VALVE LOWER BEARING
(a) Check the bearing of the rack housing for pit-marks or damage.
If faulty, replace the rack & pinion power steering gear.