Hydraulic Power Steering

DISASSEMBLY
Follow disassembly steps outlined in illustration.





Lubrication and sealing points.

NOTE: Disassembly service points as follows:





a. Tie rod/tab washer removal (8 & 9).
Unstake the tab washer which fixes the tie rod and rack with a chisel.





b. Rack support cover removal (11).
Using the special tool, remove the rack support cover from the gear box.





c. Oil seal/pinion and valve assembly removal (17 & 18).
Using a plastic hammer, gently tap the pinion to remove it.





d. Seal ring removal (19 & 29).
Cut the seal ring and remove it from the pinion and valve assembly and the rack.

CAUTION: When cutting the seal ring, be careful not to damage the pinion and valve assembly or the rack.





e. Ball bearing/oil seal removal (20 & 21).
Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously.





f. Circlip removal (23).
1. Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing.
2. Turn the rack stopper counterclockwise to remove the circlip.

CAUTION: Note that if the rack stopper is first turned counterclockwise, the circlip will get caught in the slot in the housing and the rack stopper will not turn.





g. Rack removal (26).
Pull out the rack slowly.
At this time also take out the rack stopper and the rack bushing simultaneously.





h. Oil seal removal (28).
Partially bend oil seal and remove from rack bushing.

CAUTION: Do not damage oil seal press fitting surface.





i. Ball bearing removal (31).
Use a brass bar or special tool to remove the ball bearing from the gear housing.





j. Needle roller bearing removal (32).
Use the special tool to remove the needle roller bearing from the rack housing.

CAUTION: Do not open special tool excessively, or the inner surface will be damaged.





k. 0il seal/back-up washer removal (33 & 34).
Use a piece of pipe or similar tool to remove the back-up washer and oil seal from the gear housing.

CAUTION: Be careful not to damage the inner surface of the rack cylinder of the gear housing.

INSPECTION
Rack
1. Check the rack tooth surfaces for damage or wear.
2. Check the oil seal contact surfaces for uneven wear.
3. Check the rack for bends.

Pinion And Valve Assembly
1. Check the pinion gear tooth surfaces for damage or wear.
2. Check for worn or defective seal ring.

Bearing
1. Check for roughness or abnormal noise during bearing operation.
2. Check the bearing for play.
3. Check the needle roller bearings for roller slip-off.

Others
1. Check the cylinder inner surface of the rack housing for damage.
2. Check the boots for damage, cracking or deterioration.
3. Check the rack support for uneven wear or dents.
4. Check the rack bushing for uneven wear or damage.

ASSEMBLY
Assembly in reverse order as Disassembly.

NOTE: Assembly service points as follows:





a. Back-up washer/oil seal installation (33 & 34).
1. Apply a coating of the specified fluid to the outside of the oil seal.
Specified fluid: Automatic transmission Fluid "DEXRON II"
2. Using the special tools, press the back-up washer and the oil seal into the rack housing to the specified position (where the upper surface of press-in guide coincides with the stepped part of the press-in tool).





b. Needle roller bearing installation (32).
1. Apply specified fluid to housing, bearing and oil seal press fitting surface.
Specified fluid: Automatic transmission Fluid "DEXRON II"
2. Press fit needle roller bearing with special tools.

CAUTION: Press fit straight as valve housing is aluminum.





c. Ball bearing installation (31).





d. Oil seal/o-ring installation (27 & 28).
1. Apply a coating of the specified fluid to the outside of the oil seal and O-ring.
Specified fluid: Automatic transmission Fluid "DEXRON II"
2. Use special tool to press fit oil seal until touches rack bush end.

e. Rack installation (26).
1. Apply a coating of multipurpose grease to the rack teeth face.





CAUTION: Do not grease the vent hole in the rack.





2. Cover rack serrations with special tool.
3. Apply specified fluid on special tool.
Specified fluid: Automatic transmission Fluid "DEXRON II"
4. Match oil seal centre with rack to prevent retainer spring from slipping and slowly insert rack from power cylinder side.





f. Rack bushing installation (25).
Wrap the rack end with plastic tape, apply a coating of the specified fluid, and then install the rack bushing and rack stopper.
Specified fluid: Automatic transmission Fluid "DEXRON II"

CAUTION: Do not allow oil seal retainer spring to slip out.





g. Circlip installation (23).
Insert circlip to rack stopper hole through cylinder hole. Turn rack stopper clockwise and insert circlip firmly.

CAUTION: Insert circlip to rack stopper hole while turning rack stopper clockwise.





h. Oil seal installation (21).
Apply a coating of the specified fluid to the outside of the oil seal. Using the special tools, press the oil seal into the valve housing.
Specified fluid: Automatic transmission Fluid "DEXRON II"





i. Ball bearing installation (20).
Apply a coating of the specified fluid to the outside of the ball bearing. Using the special tools, press the oil seal into the valve housing.
Specified fluid: Automatic transmission Fluid "DEXRON II"





j. Seal ring installation (19).
Because the seal rings expand at the time of installation, tighten after installation by using the special tool to compress the rings, or press down by hand.





k. Oil seal installation (17).
Using the special tool, press the oil seal into the valve housing.

CAUTION: In order to eliminate a seal malfunction at the valve housing alignment surface, the upper surface of the oil seal should project outward approximately 1 mm (.04 in.) from the housing edge surface.





l. End plug installation (14).
1. Apply the specified sealant to the threaded part of the end plug.
Specified sealant: 3M ATD Part No. 8663 or equivalent
2. Secure the threaded portion of the end plug at two places by using a punch.

m. Total pinion torque adjustment.





1. Position rack at its center. Tighten rack support cover to 15 Nm (11 ft. lbs.).
2. In neutral position, rotate pinion shaft clockwise one turn/4-6 seconds with special tool. Return rack support cover 30-60 and adjust torque to the standard value.





3. Using the special tools, rotate the pinion gear at the rate of one rotation in approximately 4 to 6 seconds to check the total pinion torque.
Standard value: 0.7-1.4 Nm (6-12 inch lbs.)
[Change in torque: 0.4 Nm (3 inch lbs.)]

CAUTION:
- When adjusting, set the standard value at its highest value.
- Assure no ratcheting or catching when operating rack towards the shaft direction.

NOTE: When it cannot be adjusted within the specified return angle, check rack support cover components or replace.

4. After adjusting, lock rack support cover with lock nut.





n. Tab washer/tie rod installation (8 & 9).
After installing tie rod to rack, fold tab washer end (2 locations) to tie rod notch.

o. Bellows band installation (6).





1. Touch pliers against the concave section of the bellows band and tighten the bellows band.





2. Use a plastic hammer or similar to bend the convex section of the bellows band as shown in the illustration.





p. Tie rod end installation (4).
Screw in tie rod end to have the shown dimension. Lock with lock nut.