Disassembly and Assembly
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.
Note: 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 to 2.5 mm (0.079 to 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. Remove rack seal ring.
a. Using a heat gun, heat rack seal to approximately 40°C (104°F).
b. Remove rack seal ring.
Be careful not to damage rack.
11. Remove center bushing and rack oil seal using tape wrapped socket and extension bar.
Do not scratch inner surfaces of pinion housing.
INSPECTION
Thoroughly clean all parts in cleaning solvent or automatic transmission fluid type DEXRON (TM) III or equivalent. Blow dry with compressed air, if available.
Boot
a. Check condition of boot. If cracked excessively, replace it.
b. Check boots for accumulation of power steering fluid.
Rack
Thoroughly examine rack gear. If damaged, cracked or worn, replace it.
Pinion Assembly
a. Thoroughly examine pinion gear. If pinion gear is damaged, cracked or worn, replace it.
b. 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.
Tie-Rod Outer And Inner Sockets
a. Check tie-rod outer and inner ball joints swinging force "A"
b. Check tie-rod outer ball joint rotating torque "B".
c. Check tie-rod outer and inner ball joints axial end play "C".
d. Check condition of dust cover. If cracked excessively, replace outer tie-rod.
ASSEMBLY
1. Using a heat gun, heat new teflon rack sea[ ring to approximately 40°C (104°F). Then place it onto rack.
2. Using tool, compress rack seal ring securely on rack.
Always insert Tool from the rack gear side.
3. Insert new rack oil seal.
Note: 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. 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".
8. Coat seal lip of new pinion oil seal with multi-purpose grease. Install it into pinion housing of gear with a suitable tool.
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. Install new pinion seal ring (made of Teflon) on pinion gear assembly.
a. Using a heat gun, heat pinion seal ring to approximately 40°C (104°F) before installing it onto pinion gear assembly.
b. 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.
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. Install rear cover cap so that protrusion of rear housing cover is positioned as shown in figure.
Be careful not to damage worm ring and oil seal.
15. Install diaphragm spring into gear housing.
Note: 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.
18. Tighten outer socket lock nut.
Tie-rod length "L".
19. Measure rack stroke.
Rack stroke "S".
20. Before installing boot, coat the contact surfaces between boot and tie-rod with grease.
21. Install boot clamps.
a. Wrap boot clamp around boot groove twice.
b. To tighten clamp, place a screwdriver through both rings. Twist rings 4 to 4-1/2 turns while pulling with a force of approx. 98 N (10 kg, 22 lbs.).
Twist boot clamp in the direction shown in figure at left.
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.
ADJUSTMENT
Adjust pinion rotating torque as follows:
1. Set rack to the neutral position without fluid in the gear.
2. Coat the adjusting screw with locking sealant and screw it in.
3. Lightly tighten lock nut.
4. Tighten adjusting screw to a torque of 4.9 to 5.9 Nm (50 to 60 kg-cm, 43 to 52 inch lbs.).
5. Loosen adjusting screw, then retighten it to 0.2 Nm (2 kg-cm, 1.7 inch lbs.).
6. Move rack over its entire stroke several times.
7. Measure pinion rotating torque within the range of 180° from neutral position.
Stop the gear at the point of maximum torque.
8. Loosen adjusting screw, then retighten it to 4.9 Nm (50 kgf-cm, 43 inch lbs.).
9. Loosen adjusting screw by 40° to 60°.
10. Prevent adjusting screw from turning, and tighten lock nut to specified torque.
11. Check rack sliding force on vehicle as follows:
a. Install steering gear onto vehicle, but do not connect tie-rod to knuckle arm.
b. Connect all piping and fill with steering fluid.
c. Start engine and bleed air completely.
d. Disconnect steering column lower joint from the gear.
e. Keep engine at idle and make sure steering fluid has reached normal operating temperature.
f. Pull tie-rod slowly to move it from neutral position to ±11.5 mm (±0.453 inch) at speed of 3.5 mm (0.138 inch)/s. Check that rack sliding force is within specification.
Rack sliding force: 216 - 284 N (18 - 22 kg, 40 - 48 lbs.)
Check sliding force outside above range.
Rack sliding force: Not more than 294 N (30 kg, 66 lbs.)
If rack sliding force is not within specification, readjust by repeating adjustment procedure from the beginning.
If rack sliding force is still out of specification after readjustment, gear assembly needs to be replaced.