Reassembly
POWER STEERING: RACK AND PINION POWER STEERING GEAR:
COMPONENTS
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
SST: 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
SST: 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
SST: 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.
NOTE: 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
SST: 09950-70010
09951-07100
NOTE: 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
SST: 09950-70010
09951-07150
NOTE: 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
SST: 09950-70010
09951-07150
8. INSTALL POWER STEERING CONTROL VALVE
(a) Expand 4 new control valve rings with your fingers.
NOTE: 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
SST: 09616-00011
SST: 09631-20081
NOTE: 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.
NOTE: 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
SST: 09616-00011
SST: 09631-20081
NOTE: 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-lbf)
(m) Using SST, stop the control valve shaft rotation and install the self-locking nut.
SST: 09612-22011
SST: 09616-00011
SST: 09631-20081
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)
(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-lbf)
(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-lbf)
(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
SST: 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
SST: 09922-10010
Preload (turning) - Torque: 1.0 - 1.8 Nm (20 - 18 kgf-cm, 8.6 - 15.7 in-lbf)
(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
SST: 09922-10010
Torque: 43 Nm (440 kgf-cm, 32 ft-lbf)
NOTE: 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.
Preload (turning) - Torque: 1.0 - 1.8 Nm (10 - 18 kgf-cm, 8.6 - 15.7 in-lbf)
(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-lbf)
NOTE: Use SST 09922-10010 in the direction shown in the illustration.
- 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
NOTE: 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-lbf)
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-lbf)
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.