Model: PB59K

Pre-disassembly Inspection and Adjustment
Before disassembling power steering gear component parts, make sure there is no oil leakage around sealing portion and check steering turning torque as follows:
Check sealing portion.
^ Sector shaft cover O-ring
^ Sector shaft U-packing
^ Sector shaft oil seal
^ Rear housing O-ring
^ Gear housing O-ring
Discard any oil seals and O-rings which have been removed. Replace oil seals and O-rings if sealing surface is deformed or cracked.

TURNING TORQUE MEASUREMENT
1. Measure turning torque at 360° position.





a. Install steering gear on Tool.
b. Turn stub shaft all the way to right and left several times.





c. Measure turning torque at 360° position from straight-ahead position with Tools.
Turning torque at 360°: 0.15 - 0.78 mm (1.5 - 8.0 kg-cm, 1.3 - 6.9 inch lbs.)





d. Measure turning torque at straight-ahead position.
Straight-ahead position is a position where stub shaft is turned 2.14 turns (two full turns and 50°) from lock position
Turning torque at straight-ahead position: 0.25 - 1.32 Nm (25 - 13.5 kg-cm, 2.3 - 11.6 inch lbs.) higher than turning torque at 360°
Maximum turning torque: 1.03 - 1.47 Nm (10.5 - 15 kg-cm, 9.2 - 13.0 inch lbs.)
If turning torque is not within specifications, adjust by turning curator





2. Tighten adjusting screw lock nut with tools.

Disassembly
Before disassembly, measure turning torque.
If not within specifications, replace steering gear assembly.

CAUTION: Oil sealing parts and snap ring must not be used again after removal.





1. Place steering gear in a vise with Tool.
2. Set worm gear in straight-ahead position.
3. Loosen (do not remove) sector shaft cover bolt.





4. Knock out end of sector shaft with a plastic hammer.
5. Remove sector shaft by hand.





6. Remove oil seal.
7. Remove U-packing.

CAUTION: When removing oil seal and U-packing, be careful not to scratch gear housing.





8. Remove lock nut, then loosen adjusting screw using a screw driver. Separate sector cover and sector shaft.





9. Remove O-ring.
10. Remove U-packing.

CAUTION:
^ When removing U-packing, be careful not to scratch sea for cover, needle bearing, etc.
^ Needle bearing cannot be disassembled. If it is damaged remove sector cover assembly.

11. Remove dust seal.





12. Remove rear housing bolts.
13. Remove rear housing together with worm gear assembly.

CAUTION: Worn gear assembly cannot be disassembled. When it is removed, be careful not to disengage worm gear from shaft or allow it to drop.

14. Remove teflon ring and O-ring of worm gear assembly.

Assembly





1. Install new O-ring on worm gear assembly.
^ Apply a thin coat of ATF to new O-ring.
2. Install new teflon ring on worm gear assembly.
^ Make sure that teflon ring is seated in correct position.
3. Install new O-rings into rear housing.





4. Install worm gear assembly with rear housing into the gear housing.

CAUTION:
^ Apply a thin coat of ATF inside gear housing and piston before insertion.
^ Be careful not to damage teflon ring at piston end when inserting worm gear assembly into gear housing.





5. Gradually tighten rear housing bolts in a criss-cross fashion.





6. Install new O-ring into sector shaft cover.
^ Before installing, apply a thin coat of ATF to O-ring.
7. Install new U-packing into sector shaft cover.
^ Before installing, apply a thin coat of ATF to U-packing.
^ Direct grooved side of U-packing to needle bearing.





8. Install sector shaft into sector shaft cover. Set adjusting screw to its outermost position.
^ Before installing sector shaft, apply multi-purpose grease to adjusting screw and adjusting screw shim.





9. Install new oil seal into gear housing with suitable tool.
^ Before installing oil seal, apply multi-purpose grease to oil seal lips.





10. Set piston rack at straight-ahead position.
Turn piston rack about 10° to 15° toward yourself with your finger.
This enables smooth insertion of sector gear.
11. Gradually insert sector shaft into gear housing.





12. Tighten sector shaft cover bolts.
13. Set worm gear turning torque by turning sector shaft adjusting screw and locking with lock nut.
^ If set and adjusting turning torque is considerably different from the value before disassembly, replace the entire assembly.
14. Check sector shaft end play in neutral position.
End play: Less than 0.1 mm (0.004 inch)
If not within specification, adjust it with adjusting screw.
15. Check worm gear preload. If not within specification, readjust it.