Disassembly and Assembly
DISASSEMBLYCAUTION: When using a vise, do not overtighten it.
1. Secure PS gear assembly in vise. Using Special Service Tool (SST) 09612 - 00012, secure the gear assembly in a vise.
2. Remove 2 turn pressure tubes.
a. Using SST 09633 - 00020 , remove the tube.
b. Remove the 2 O-rings from the tube.
3. Remove RH and LH tie rod ends and lock nuts.
a. Place matchmarks on the tie rod end and rack end.
b. Loosen the lock nut.
4. Remove RH and LH clips, rack boots and clamps. Using a screwdriver, loosen the clamp.
CAUTION: Be careful not to damage the boot. Mark the RH and LH boots.
5. Remove RH and LH rack ends and claw washers.
a. Using a screwdriver and hammer, unstake the washer.
CAUTION: Avoid any impact to the steering rack.
b. Using a spanner (24 mm) to hold the steering rack steady, and using SST 09922 - 10010, remove the rack end.
CAUTION:
- Use SST 09922 - 10010 in the direction shown in the illustration.
- Mark the RH and LH rack ends.
c. Remove the washer from the rack end.
6. Remove rack guide spring cap lock nut. Using SST 09922 - 10010, remove the nut.
CAUTION: Use SST 09922 - 10010 in the direction shown in the illustration.
7. Remove rack guide spring cap, rack guide spring, rack guide and rack guide seat.
a. Using SST 09631 - 10021, remove the cap.
b. Remove the seat from the-guide.
8. Remove rack housing cap.
9. Remove self-locking nut. Using SST 09616 - 00010 to stop the control valve shaft rotating. remove the nut.
10. Remove dust cover.
11. Remove control valve housing with control valve assembly.
a. Place matchmarks on the valve housing and rack housing.
b. Remove the 2 bolts.
c. Remove the gasket from the rack housing.
12. Remove control valve assembly.
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
b. Press out the valve assembly with the oil seal.
CAUTION:
- Place a shop rag between the valve housing and the blocks. Be careful not to drop the valve assembly.
- Be careful not to damage the oil seal lip.
13. Remove oil seal. Remove the oil seal from the control valve assembly.
14. Remove rack housing No. 2 bracket and grommet.
a. Place matchmarks on the bracket and rack housing.
b. Using a screwdriver, pry the clamp of the bracket.
c. Remove the grommet from the bracket.
15. Remove cylinder end stopper.
a. Using SST 09631-10021, turn the stopper clockwise until the wire end is visible through the service hole.
b. Using SST 09631-10021, turn the stopper counterclockwise, and remove the wire.
16. Remove steering rack and bushing.
a. Using a brass bar and hammer, tap out the rack with the bushing.
b. Remove the bushing from the rack.
c. Remove the O-ring from the bushing.
17. Remove oil seal. Using SST 09950 - 60010 (09951 - 00290), 09950 - 70010 (09951 - 07360), press out the oil seal.
INSPECTION
CAUTION: When using a vise, do not overtighten it.
1. Inspect steering rack.
a. Using a dial indicator, check the rack for runout and for teeth wear and damage.
Runout:
Maximum: 0.30 mm (0.0118 inch).
b. Check the back surface for wear and damage.
2. If necessary, replace oil seal and bearing.
a. Using Special Service Tool (SST) 09950 - 60010 (09951 - 00250), 09950 - 70010 (09951 - 07200), press out the oil seal and bearing from the control valve housing.
b. Coat a new oil seal lip with power steering fluid.
c. Using SST 09950 - 60010 (09951 - 00180, 09951 - 00320, 09952 - 06010), 09950 - 70010 (09951 - 07200), press in the oil seal.
CAUTION: Make sure to install the oil seal facing the correct direction.
d. Coat a new bearing with molybdenum disulfide lithium base grease.
e. Using SST 09950 - 60010 (09951 - 00180, 09951 - 00340, 09952 - 06010), 09950 - 70010 (09951 - 07200), press in the bearing.
3. If necessary, replace 2 bearings.
a. Using a brass bar and hammer, tap out the bearing from the rack housing.
b. Using SST 09950 - 60010 (09951 - 00260), 09950 - 70010 (09951 - 072003, press out the bearing from the rack housing.
c. Coat a new bearing with molybdenum disulfide lithium base grease.
d. Using SST 09950 - 60010 (09951 - 00250, 09951 - 00310, 09952 - 06010), 09950 - 70010 (09951 - 07200), press in the bearing.
e. Coat a new bearing with molybdenum disulfide lithium base grease.
f. Using SST 09950 - 60010 (09951 - 00320), 09950 - 70010 (09951 - 07200), press in the bearing.
4. If necessary, replace oil seal.
a. Using SST 09527 - 20011, 09612 - 24014 (09613 - 22011), remove the oil seal from the bushing.
CAUTION: Be careful not to damage the bushing.
b. Coat a new oil seal lip with power steering fluid.
c. Using SST 09950 - 60010 (09951 - 00240, 09951 - 00400, 09952 - 06010), press in the oil seal.
CAUTION: Make sure to install the oil seal facing the correct direction.
5. If necessary, replace teflon ring and O-ring
a. Using a screwdriver, remove the teflon ring and O-ring from the steering rack.
CAUTION: Be careful not to damage the groove for the teflon ring.
b. Coat a new O-ring with power steering fluid and install it.
c. Expand a new teflon ring with your fingers.
CAUTION: Be careful not to over-expand the ring.
d. Coat the ring with power steering fluid.
e. Install the ring to the steering rack, and snug it down with your fingers.
6. If necessary, replace teflon rings.
a. Using a screwdriver, remove the 4 rings from the control valve assembly.
CAUTION: Be careful not to damage the grooves for the teflon ring.
b. Expand 4 new teflon rings with your fingers.
CAUTION: Be careful not to over-expand the teflon ring.
c. Coat the rings with power steering fluid.
d. Install the rings to the control valve assembly, and snug them down with your fingers.
e. Carefully slide the tapered end of SST 09631 - 20081 over the rings to seat them.
CAUTION: Be careful not to damage the rings.
ASSEMBLY
CAUTION: When using a vise, do not overtighten it.
1. Coat with power steering fluid or molybdenum disulfide lithium base grease.
2. Install oil seal.
a. Coat a new oil seal lip with power steering fluid.
b. Using Special Service Tool (SST) 09950 - 60010 (09951 - 00240, 09951 - 00430, 09952 - 06010), 09950 - 70010 (09951 - 07360), press in the oil seal.
CAUTION:
- Make sure to install the oil seal facing the correct direction.
- Take care that the oil seal does not get reversed as you install it.
3. Install steering rack.
a. Install SST 09631 - 33010 to the rack.
NOTE: If necessary, scrape the burrs off the rack tee end and burnish.
b. Coat the SST with power steering fluid.
c. Install the rack into the rack housing.
CAUTION: Be careful not to damage the oil seal lip.
d. Remove SST.
4. Install bushing.
a. Coat a new O-ring with power steering fluid and install it to the bushing.
b. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
c. Install the bushing.
CAUTION:
- Make sure to install the bushing facing the correct direction.
- Be careful not to damage the oil seal lip.
5. Install cylinder end stopper.
a. Align the installation hole for the wire of the stopper with the slot of the rack housing.
b. Install a new wire into the stopper.
c. Using SST 09631 - 10021, turn the stopper clockwise 450° ± 50°.
6. Air tightness test.
a. Install SST 09631 - 12071 to the rack housing.
b. Apply 53 kPa (15.75 inch Hg) of vacuum for about 30 seconds.
c. Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the oil seals.
7. Install rack housing No. 2 bracket and grommet.
a. Install the grommet to the bracket.