Steering Gear: Service and Repair

RACK AND PINION POWER STEERING GEAR

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

REMOVAL

NOTICE: When installing, coat the parts indicated by the arrow with power steering fluid or molybdenum disulfide lithium base grease.

1. PRECAUTION
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. INSPECT CENTER FRONT WHEEL
4. REMOVE STEERING PAD
5. REMOVE STEERING WHEEL ASSEMBLY
6. REMOVE FRONT WHEELS
7. REMOVE ENGINE UNDER COVER LH
8. REMOVE ENGINE UNDER COVER RH

9. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect tie rod end sub-assembly LH from the steering knuckle.
SST 09628-62011

10. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
SST 09628-62011

HINT: Remove the RH side by the same procedures as the LH side.

11. REMOVE COLUMN HOLE COVER SILENCER SHEET
12. DISCONNECT STEERING INTERMEDIATE SHAFT

13. DISCONNECT PRESSURE FEED TUBE ASSEMBLY
(a) Using SST, disconnect the pressure feed tube assembly.
SST 09023-38401

14. DISCONNECT RETURN TUBE SUB-ASSEMBLY
(a) Using SST, disconnect the return tube sub-assembly.
SST 09023-38401

(b) Remove the bolt and disconnect the tube clamp.

15. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
(a) Remove the nut and disconnect the front stabilizer link assembly LH from the stabilizer bar.

16. REMOVE FRONT STABILIZER LINK ASSEMBLY RH

HINT: Remove the RH side by the same procedures as the LH side.

17. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
(a) Remove the bolt and 2 nuts and disconnect the front suspension arm sub-assembly lower No. 1 LH from the lower ball joint.

18. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

HINT: Remove the RH side by the same procedures as the LH side.

19. REMOVE HOOD SUB-ASSEMBLY
20. REMOVE CYLINDER HEAD COVER NO. 2

21. SUSPEND ENGINE ASSEMBLY
(a) Install the 2 engine hangers with the bolts in the correct direction.

Parts No.:

Attach the engine chain hoist to the engine hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other parts.

22. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Remove the 2 bolts and disconnect the center member from the engine mounting insulator FR.
(b) Remove the 2 bolts and disconnect the center member from the frame.

(c) Remove the bolt and 3 nuts, disconnect the engine mounting insulator RR from the crossmember.
(d) Using a transmission jack, support the crossmember.
(e) Remove the 4 bolts and front suspension crossmember sub-assembly with the steering gear assembly.

23. REMOVE STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1

24. REMOVE STEERING INTERMEDIATE SHAFT
(a) Place matchmarks on the intermediate shaft with control valve.
(b) Remove the bolt and steering intermediate shaft.

25. REMOVE RACK & PINION POWER STEERING GEAR ASSEMBLY
(a) Remove the 4 bolts and rack & pinion power steering gear assembly from the crossmember.

DISASSEMBLY

1. FIX RACK & PINION POWER STEERING GEAR ASSEMBLY
(a) Using SST, secure the rack & pinion power steering gear assembly in a vise.
SST 09612-00012

2. REMOVE STEERING LEFT TURN PRESSURE TUBE
(a) Using SST, remove the left turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the left turn pressure tube.

3. REMOVE STEERING RIGHT TURN PRESSURE TUBE
(a) Using SST, remove the right turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the right turn pressure tube.

4. REMOVE TIE ROD END SUB-ASSEMBLY LH
(a) Place matchmarks on the tie rod end with rack end.
(b) Loosen the lock nut, and remove the tie rod end and lock nut.

5. REMOVE TIE ROD END SUB-ASSEMBLY RH

HINT: Remove the RH side by the same procedures as the LH side.

6. REMOVE STEERING RACK BOOT NO. 2
(a) Remove the steering rack boot clip.
(b) Using a screwdriver, remove the clamp and steering rack boot No. 1.

7. REMOVE STEERING RACK BOOT NO. 1

HINT: Remove the steering rack boot No. 2 by the same procedures as the No. 1.

8. REMOVE STEERING RACK END SUB-ASSEMBLY
(a) Using a wrench, hold the steering rack steadily and using SST, remove the rack end.
SST 09922-10010

NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

HINT: Mark the RH and LH rack ends.

(b) Use the same manner described above to the other side.

9. REMOVE RACK GUIDE
(a) Using SST, remove the rack guide spring cap nut.

NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

(b) Using a hexagon wrench (19 mm), remove the rack guide spring cap.
(c) Remove the conical spring, rack guide spring and rack guide.

10. REMOVE POWER STEERING CONTROL VALVE
(a) Remove the rack housing cap.

(b) Using SST, hold the control valve shaft and remove the self-locking nut.
SST 09616-00011

(e) To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
(f) Using a plastic hammer, remove the control valve with oil seal from the control valve housing.
(g) Remove the oil seal from the control valve.

(h) Using a screwdriver, remove the 4 control valve rings.

NOTICE: Be careful not to damage the grooves for the control valve ring.

11. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL
(a) Using SST and a press, remove the control valve upper bearing and upper oil seal from the control valve housing.
SST 09950-70010 (09951-07150), 09950-60010 (09951-00260)

12. REMOVE CYLINDER END STOPPER
(a) Using snap ring pliers, remove the snap ring.
(b) Pull out the cylinder end stopper.

13. REMOVE POWER STEERING RACK
(a) Using SST and a press, remove the steering rack with the bushing.

NOTICE: Take care not to drop the steering rack.

(b) Remove the O-ring from the bushing.
SST 09612-24014 (09613-22011)

14. REMOVE POWER STEERING RACK BUSH
(a) Remove the power steering rack bush from the power steering rack.
(b) Using SST, remove the rack bush oil seal.
SST 09612-24014 (09613-22011)

15. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL
(a) Using SST and a press, remove the power steering cylinder tube oil seal.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07360)

16. REMOVE POWER STEERING CONTROL VALVE LOWER BEARING
(a) Using SST and a press, remove the power steering control valve lower bearing.
SST 09950-70010 (09951-07100)

(b) Using SST and a press, remove the power steering control valve center bearing.

INSPECTION

1. INSPECT TIE ROD END SUB-ASSEMBLY LH
(a) Secure the tie rod end LH in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint stud back and forth 5 times.
(d) Using a torque wrench, turn the nut continuously at a rate of 2 - 4 seconds per 1 turn and take the torque reading of the 5th turn.
Torque:
Turning torque 0.49 - 3.43 Nm (5.0 - 35 kgf/cm, 4.34 - 30.38 in. lbs.)

2. INSPECT TIE ROD END SUB-ASSEMBLY RH

HINT: Inspect the RH side by the same procedures as the LH side.

3. INSPECT POWER STEERING RACK
(a) Using a screwdriver, remove the O-ring from the power steering rack bush sub-assembly.
(b) Using a dial indicator, check the steering rack for runout and for teeth wear and damage.
Maximum runout: 0.1 mm (0.004 in.)
(c) Check the back surface for wear and damage.

REASSEMBLY

1. INSTALL POWER STEERING CONTROL VALVE LOWER BEARING
(a) Coat a new bearing with molybdenum disulfide lithium base grease.
(b) Using SST and a press, install in the control valve center bearing.
SST 09950-60010 (09951-00220, 09951-00280, 09952-06010), 09950-70010 (09951-07100)

(c) Coat a new bearing with molybdenum disulfide lithium base grease.
(d) Using SST and a press, install the control valve lower bearing.
SST 09950-60010 (09951-00220, 09951-00280, 09952-06010), 09950-70010 (09951-07100)

2. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL
(a) Coat a new power steering cylinder tube oil seal lip with power steering fluid.
(b) Using SST and a press, install the power steering cylinder tube oil seal.
SST 09950-60010 (09951-00240, 09951-00400, 09952-06010), 09950-70010 (09951-07360)

NOTICE:
^ Make sure that the power steering cylinder tube oil seal is installed facing in the correct direction.
^ Take care so that the power steering cylinder tube oil seal will not be reversed with you install it.

3. INSTALL POWER STEERING RACK
(a) Coat a new power piston O-ring with power steering fluid and install it to the steering rack.
(b) Coat a new power piston oil seal with power steering fluid.
(c) Expand the power piston oil seal with your fingers.

NOTICE: Be careful not to expand the power piston oil seal excessively.

(d) Install the power piston oil seal to the steering rack, and settle it down with your fingers.
SST 09631-16020

(e) Install SST to the steering rack.
SST 09631-16020

HINT: If necessary, scrape the burrs off the steering rack teeth end and burnish.

(f) Coat the SST with power steering fluid.
(g) Install the steering rack into the rack housing.
(h) Remove the SST.
SST 09631-16020

4. INSTALL POWER STEERING RACK BUSH
(a) Using SST and a press, install the rack bush oil seal to the power steering rack bush.
SST 09950-60010 (09951-00400), 09950-70010 (09951-07100)

NOTICE: Make sure that the rack bush oil seal is installed facing in the correct direction.

(b) Coat a new O-ring with power steering fluid and install it to the power steering rack bush.

(c) To prevent rack bush oil seal lip damage, wind vinyl tape around the steering rack end, and apply power steering fluid.
(d) Install the rack bush to the steering rack.

5. INSTALL CYLINDER END STOPPER
(a) Using SST and a hammer, drive in the cylinder end stopper.
SST 09612-22011
(b) Using snap ring pliers, install a new snap ring to the rack housing.

6. INSTALL RACK & PINION POWER STEERING GEAR ASSEMBLY
(a) Install SST to the rack housing.
SST 09631-12071 (09633-00010)
(b) Apply vacuum of 53 kPa (400 mmHg, 15.75 in. Hg) for about 30 seconds.
(c) Check that there is no change in the vacuum. If there is a change in the vacuum, check the installation of the oil seals.

7. INSTALL POWER STEERING CONTROL VALVE UPPER OIL SEAL
(a) Coat an upper bearing and a new upper oil seal with power steering fluid.
(b) Using SST and a press, install the upper oil seal.
SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Make sure that the oil seal is installed facing in the correct direction.

(c) Using SST and a press, install the upper bearing.
SST 09950-60010 (09951-00190, 09951-00360, 09952-06010), 09950-70010 (09951-07150)

8. INSTALL POWER STEERING CONTROL VALVE
(a) Expand 4 new control valve rings with your fingers.

NOTICE: Be careful not to over expand the valve ring.

(b) Coat the 4 control valve rings with power steering fluid.
(c) Install the 4 control valve rings to the control valve, and settle them down with your fingers.

(d) Carefully slide the tapered end of SST over the control valve rings until they fit to the control valve.
SST 09612-22011, 09616-00011, 09631-20081

NOTICE: Be careful not to damage the control valve rings.

(e) To prevent oil seal lip damage, wind vinyl tape around the serrated part of the control valve.
(f) Install the control valve to the valve housing.

NOTICE: Be careful not to damage the control valve rings and oil seal lip.

(g) Coat a new oil seal lip with power steering fluid.
(h) Using SST and a press, install the oil seal.
SST 09612-22011, 09616-00011, 09631-20081

NOTICE: Make sure that the oil seal is installed facing in the correct direction.

(i) Apply grease to the needle bearing.
(j) Install a new gasket to the valve housing.
(k) Wind vinyl tape around the serration part of the control valve.
(l) Install the valve housing to the rack housing with the 2 bolts.
Torque: 18 Nm (185 kgf/cm, 13 ft. lbs.)

(m) Using SST, stop the control valve shaft rotation and install the self-locking nut.
SST 09612-22011, 09616-00011, 09631-20081
Torque: 25 Nm (250 kgf/cm, 18 ft. lbs.)
(n) Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(o) Install the rack housing cap.
Torque: 59 Nm (600 kgf/cm, 43 ft. lbs.)

(p) Using a punch and a hummer, stake the rack housing cap and rack housing.

9. INSTALL RACK GUIDE
(a) Apply molybdenum disulfide lithium base grease to the contact surface of the power steering rack and of the rack guide.
(b) Install the rack guide and compression spring to the rack housing.
(c) Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(d) Temporarily install the rack guide spring cap.

10. INSPECT TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.
(b) Torque the rack guide spring cap.
Torque: 25 Nm (250 kgf/cm, 18 ft. lbs.)
(c) Back off the rack guide spring cap 12°.

(d) Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00011, 09922-10010
(e) Loosen the rack guide spring cap until the rack guide spring is not functioning.

(f) Using SST and torque wrench, tighten the rack guide spring cap until the preload is within the specification.
SST 09616-00011, 09922-10010
Torque:
Preload (turning) 1.0 - 1.8 Nm (20 - 18 kgf/cm, 8.6 - 15.7 ft. lbs.)
(g) Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(h) Temporarily install the lock nut.

(i) Using a hexagon wrench (19 mm), hold the rack guide spring cap and using SST, torque the nut.
SST 09616-00011, 09922-10010
Torque: 43 Nm (440 kgf/cm, 32 ft. lbs.)

NOTICE: Use SST 09922-0010 in the direction shown in the illustration.

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).

(j) Recheck the total preload.
Torque:
Preload (turning) 1.0 - 1.8 Nm (10 - 18 kgf/cm, 8.6 - 15.7 ft. lbs.)
(k) Remove the RH and LH rack ends.

11. INSTALL STEERING RACK END SUB-ASSEMBLY
(a) Using a wrench, hold the steering rack steadily and using SST, install the 2 rack ends.
SST 09922-10010
Torque: 62 Nm (630 kgf/cm, 46 ft. lbs.)

NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

HINT:
^ Using SST, hold the rack and install the rack end sub-assembly.
^ Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).

(b) Ensure that the steering rack hole is not clogged with grease.

HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and steering wheel is turned.

12. INSTALL STEERING RACK BOOT NO. 2
(a) Install the steering rack boot No. 2.
(b) Using SST, tighten the steering rack boot No. 2 clamp, as shown in the illustration.
SST 09521-24010
Clearance: 2.0 mm (0.079 in.) or less

NOTICE: Be careful not to damage the boot.

(c) Using a pliers, install the rack boot clip.
13. INSTALL STEERING RACK BOOT NO. 1

HINT: Install the rack boot No.1 by the same procedures as the rack boot No. 2.

14. INSTALL TIE ROD END SUB-ASSEMBLY LH
(a) Screw the lock nut and tie rod end sub-assembly LH onto the rack end until the matchmarks are aligned.

HINT: After adjusting toe-in, torque the lock nut.

15. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT: Install the RH side by the same procedures as the LH side.

16. INSTALL STEERING RIGHT TURN PRESSURE TUBE
(a) Coat 2 new O-rings with power steering fluid and install them to the right turn pressure tube.
(b) Using SST, install the right turn pressure tube to the steering gear assembly.
SST 09023-38201
Torque: 12 Nm (120 kgf/cm, 9 ft. lbs.)

HINT:
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
^ This torque value is effective in the case that SST is parallel to a torque wrench.

17. INSTALL STEERING LEFT TURN PRESSURE TUBE
(a) Coat 2 new O-rings with power steering fluid and install them to the left turn pressure tube.
(b) Using SST, install the left turn pressure tube to the steering gear assembly.
SST 09023-38201
Torque: 12 Nm (120 kgf/cm, 9 ft. lbs.)

HINT:
^ Use a toque wrench with a fulcrum length of 345 mm (13.58 in.).
^ This torque value is effective in the case that SST is parallel to a torque wrench.

INSTALLATION
1. INSTALL RACK & PINION POWER STEERING GEAR ASSEMBLY
(a) Install the power steering gear assembly with the 4 bolts and nuts.
Torque: 58 Nm (590 kgf/cm, 43 ft. lbs.)

NOTICE:
^ The 4 bush must be securely installed to the power steering gear assembly.
^ When tightening the installation bolt for power steering gear, the bush should not bitten in.

2. INSTALL STEERING INTERMEDIATE SHAFT
(a) Align the matchmarks on the steering intermediate shaft with steering pinion shaft.
(b) Install the bolt.
Torque: 35 Nm (360 kgf/cm, 26 ft. lbs.)

3. INSTALL STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1

4. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Using SST, align the holes of the front suspension member RH and body, and temporarily tighten the bolt in order of A, B.
SST 09670-00010

(b) Using SST, align the holes of the front suspension member LH and body, and temporarily tighten the bolt in order of A, B.
SST 09670-00010
(c) Using SST, align the holes of the front suspension member RH and body, and torque the bolt A and B.
SST 09670-00010
Torque:
Bolt A 157 Nm (1,600 kgf/cm, 116 ft. lbs.)
Bolt B 113 Nm (1,152 kgf/cm, 83 ft. lbs.)
(d) Using SST, align the holes of the front suspension member LH and body, and torque the bolt A and B.
SST 09670-00010
Torque:
Bolt A 157 Nm (1,600 kgf/cm, 116 ft. lbs.)
Bolt B 113 Nm (1,152 kgf/cm, 83 ft. lbs.)

(e) Connect the engine mounting insulator RR to the crossmember with the bolt and 3 nuts.
Torque: 52 Nm (530 kgf/cm, 38 ft. lbs.)

(f) Install the center member to the frame with the 2 bolts.
Torque: 60 Nm (612 kgf/cm, 44 ft. lbs.)
(g) Connect the engine mounting insulator FR to the center member with the 2 bolts.
Torque: 52 Nm (530 kgf/cm, 38 ft. lbs.)

5. CONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
(a) Connect the front suspension lower arm No. 1 to the lower ball joint with the bolt and 2 nuts.
Torque: 89 Nm (910 kgf/cm, 66 ft. lbs.)

6. CONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

HINT: Use the same manner described above to the other side.

7. CONNECT FRONT STABILIZER LINK ASSEMBLY LH
(a) Connect the front stabilizer link assembly LH with the nut.
Torque: 74 Nm (750 kgf/cm, 55 ft. lbs.)

8. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT: Use the same manner described above to the other side.

9. CONNECT RETURN TUBE SUB-ASSEMBLY
(a) Using SST, connect the return tube sub-assembly.
SST 09023-38401
Torque: 23 Nm (235 kgf/cm, 17 ft. lbs.)

HINT:
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
^ This torque value is effective in case that SST is parallel to a torque wrench.

10. CONNECT PRESSURE FEED TUBE ASSEMBLY
(a) Using SST, connect the pressure feed tube assembly.
SST 09023-38401
Torque: 23 Nm (235 kgf/cm, 17 ft. lbs.)

HINT:
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).
^ This torque value is effective in case that SST is parallel to a torque wrench.

(b) Connect the tube clamp with the bolt.
Torque: 7.8 Nm (80 kgf/cm, 69 ft. lbs.)

11. CONNECT STEERING INTERMEDIATE SHAFT
12. CONNECT TIE ROD END SUB-ASSEMBLY LH
(a) Connect the tie rod end sub-assembly LH with the nut.
Torque: 49 Nm (500 kgf/cm, 36 ft. lbs.)
(b) Install a new cotter pin.

NOTICE: If the holes for a new cotter pin are not aligned, tighten the nut further up to 60°.

13. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT: Use the same manner described above to the other side.

14. INSTALL ENGINE UNDER COVER LH
15. INSTALL ENGINE UNDER COVER RH
16. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf/cm, 76 ft. lbs.)

17. INSPECT CENTER FRONT WHEEL
18. INSTALL COLUMN HOLE COVER SILENCER SHEET
(a) Install the column hole cover silencer sheet with the 2 nuts.

19. ADD POWER STEERING FLUID
20. BLEED POWER STEERING FLUID
21. INSPECT FOR POWER STEERING FLUID LEAK
22. INSTALL CYLINDER HEAD COVER NO. 2
(a) Install the cylinder head cover No. 2 with 2 nuts and 2 clips.
Torque: 7.0 Nm (71 kgf/cm, 62 ft. lbs.)

23. INSTALL HOOD SUB-ASSEMBLY
24. INSPECT HOOD SUB-ASSEMBLY
25. ADJUST HOOD SUB-ASSEMBLY
26. CENTER SPIRAL CABLE
27. INSTALL STEERING WHEEL ASSEMBLY
28. INSTALL STEERING PAD
29. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
30. INSPECT SRS WARNING LIGHT