Overhaul

DISASSEMBLY
1. Prior to disassembling, measure pinion rotating torque. Record the pinion rotating torque as a reference.

NOTE: Before measuring, disconnect gear housing tube and drain fluid. Use soft jaws when holding steering gear housing. Handle gear housing carefully, as it is made of aluminum. Do not grip cylinder in a vise.

2. Remove pinion gear.

CAUTION: Be careful not to damage pinion gear when removing pinion seal ring.

3. Remove tie rod outer sockets and boots.





4. Loosen tie rod inner socket by prying up staked portion, and remove socket.
5. Remove retainer.
6. Remove pinion assembly.
7. Use a 2 - 2.5 mm (0.079 - 0.098 inch) diameter drill to completely remove staked portion of gear housing end.





8. Remove end cover assembly with a suitable tool.
9. Draw out rack assembly.
10. Using a heat gun, heat rack seal to approximately 40° C (104° F) and remove rack seal ring.

CAUTION: Be careful not to damage rack.





11. Remove center bushing and rack oil seal using tape wrapped socket and extension bar.

CAUTION: Do not scratch inner surfaces of pinion housing.

INSPECTION

General
- Thoroughly clean all parts in cleaning solvent or Automatic Transmission Fluid (ATF) type DEXRON III, or equivalent. Blow dry with compressed air, if available.

Boot
- Check condition of boot. If cracked excessively, replace it.
- Check boots for accumulation of power steering fluid.

Rack
- Thoroughly examine rack gear. If damaged, cracked or worn, replace it.

Pinion Assembly
- Thoroughly examine pinion gear. If pinion gear is damaged, cracked or worn, replace it.
- Check that all bearings roll freely. Ensure that balls, rollers and races are not cracked, pitted or worn.

Gear Housing Cylinder
- Check gear housing cylinder bore for scratches or other damage. Replace if necessary.

Outer And Inner Sockets

Fig.1:

- Check ball joints for swinging force, tie rod outer and inner ball joints swinging force "A".
- Check ball joint for rotating torque, tie rod outer ball joint rotating torque "B"
- Check ball joints for axial end play, tie rod outer and inner ball joints axial end play "C":
- Check condition of dust cover. If cracked excessively, replace outer tie rod.





ASSEMBLY
1. Using a heat gun, heat new teflon rack seal ring to approximately 40° C (104° F). Then place it onto rack.





2. Using rack seal ring reforming tool No. KV48104400, or equivalent, compress rack seal ring securely on rack.

NOTE: Always insert Tool from the rack gear side.





3. Insert new rack oil seal. Place plastic film into rack oil seal to prevent damage by rack teeth. Do not forget to remove plastic film after rack oil seal is positioned properly.

NOTE: Make sure lips of rack oil seal face each other.





4. Install center bushing and rack oil seal with rack assembly.





5. Insert rack oil seal and end cover assembly to rack. Then tighten end cover assembly.





6. Fasten end cover assembly to gear housing by staking.





7. Set rack gear in neutral position.

Rack stroke "S": 70.5 mm (2.776 inch)





8. Coat seal lip of new pinion oil seal with multi-purpose grease and install it into pinion housing of gear with a suitable tool.

NOTE: Make sure lip of oil seal faces up when installed.





9. Install pinion bearing adjusting shim(s).

NOTE: Whenever pinion assembly, gear housing and rear housing are disassembled, replace shim(s) with new ones. Always use the same number of shim(s) when replacing.





10. Using a heat gun, heat pinion seal ring to approximately 40° C (104° F) before installing it onto pinion gear assembly. Install new pinion seal ring (made of Teflon) on pinion gear assembly. Make sure pinion seal ring is properly settled in valve groove.





11. Apply a coat of multi-purpose grease to needle bearing roller and oil seal lip.





12. Install pinion assembly to rear housing.

CAUTION: Be careful not to damage pinion oil seal.





13. Apply a coat of multi-purpose grease to new rear oil seal lip before installing rear housing.





14. Ensure that the rack is centered and install rear cover cap so that protrusion of rear housing cover is positioned as shown in figure.

CAUTION: Be careful not to damage worm ring and oil seal.





15. Install diaphragm spring into gear housing.
- Always install retainer, spring washer and diaphragm spring in that order.
- Make sure convex end (painted white) of diaphragm spring faces outward when installing.
16. Install retainer spring and adjusting screw temporarily.





17. Install new lock plate.
a. Attach lock plate (2) to side rod inner socket (1).
b. Apply locking sealant to inner socket threads (3).
c. Screw inner socket into rack (4) and tighten to specified torque.
d. Clinch two places of lock plate at rack's groove.

CAUTION: To prevent scratching the boot, remove burrs from lock plate.

Fig. 2:

18. Tighten outer socket lock nut.

Tie-rod length "L": 202.7 mm (7.98 inch)





19. Measure rack stroke.

Rack stroke "S": 70.5 mm (2.776 inch)





20. Before installing boot, coat the contact surfaces between boot and tie-rod with grease.





21. Install boot clamps.
- To install, wrap boot clamp around boot groove twice. To tighten clamp, place a screwdriver through both rings. Twist rings 4 - 4-1/2 turns while pulling with a force of approximately 98 N (22 lbs.).
- Twist boot clamp in the direction shown in figure.





- Locate twisted end of boot clamp in the range shown. (This will prevent interference with other parts.)





- After twisting boot clamp, bend twisted and diagonally so it does not contact boot.