Overhaul

DISASSEMBLY AND REASSEMBLY





Lubrication And Sealing Points

Disassembly Service Points
[A] Tie Rod/Tab Washer Removal





Unstake the tab washer which fixes the tie rod and rack with a chisel.

[B] Rack Support Cover Removal





Using the special tool, remove the rack support cover from the gear box.

[C] Oil Seal/Pinion And Valve Assembly Removal





Using a plastic hammer, gently tap the pinion to remove it.

[D] Seal Ring Removal





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





Using a socket, remove the oil seal and the ball bearing from the valve housing simultaneously.

[F] Circlip Removal





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





Pull out the rack slowly. At this time also take out the rack stopper and the rack bushing simultaneously.

[H] Oil Seal Removal





Partially bend oil seal and remove from rack bushing.

CAUTION: Do not damage oil seal press fitting surface.

[I] Ball Bearing Removal





Use a brass bar or special tool to remove the ball bearing from the gear housing.

[J] Needle Roller Bearing Removal





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] Oil Seal/Back-Up Washer Removal





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.

Reassembly Service Points
]A[ Back-Up Washer/Oil Seal Installation





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





1. Apply specified fluid to housing, bearing and oil seal press fining 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

]D[ Oil Seal/O-Ring Installation





1. Apply a coating of the specified fluid to the outside of the oil seal and 0-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





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 center with rack to prevent retainer spring from slipping and slowly insert rack from power cylinder side.

]F[ Rack Bushing Installation





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





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





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





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





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





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 (0.04 inch) from the housing edge surface.

]L[ End Plug Installation





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:
1. When adjusting, set the standard value at its highest value.
2. 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[ Washer/Tie Rod Installation





After installing tie rod to rack, fold tab washer end (2 locations) to tie rod notch.

]O[ Bellows Band Installation





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





Screw in tie rod end to have the shown dimension. Lock with lock nut.

INSPECTION
Rack Check
- Check the rack tooth surfaces for damage or wear.
- Check the oil sea[ contact surfaces for uneven wear.
- Check the rack for bends.

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

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

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

Tie Rod End Ball Joint Dust Cover Check
1. Check the dust cover for cracks or damage by pushing it with finger.
2. If the dust cover is cracked or damaged, replace the tie rod end.

NOTE: Cracks or damage of the dust cover may cause damage of the ball joint. When it is damaged during service work, replace the dust cover.

Tie Rod End Ball Joint Dust Cover Replacement





Replace the dust cover by the following procedure only if the dust cover has become damaged by accident during servicing.
1. Remove the dust cover.
2. Pack dust cover interior with multipurpose grease.
3. Apply specified sealant to dust cover lip.

Specified sealant: 3M ATD Part No. 8663 or equivalent

4. Using the special tool, install the dust cover to the tie rod end ball joint.
5. Check the dust cover for cracks or damage by pushing it with finger.