Disassembly and Assembly

POWER STEERING GEAR

Disassembly and Assembly


COMPONENT (R24K TYPE)












CAUTION:
Clean steering gear assembly with kerosene before disassembling.

DISASSEMBLY

1.Loosen outer socket lock nut, and then remove outer socket from inner socket.
2.Remove boot clamp, and then remove boot from inner socket.

CAUTION:
Do not damage inner socket and gear housing assembly when removing boot. Inner socket and gear housing assembly must be replaced if inner socket and gear housing assembly are damaged because it may allow foreign material to enter.
3.Remove inner socket from rack assembly while holding the flat portion of the rack next to the inner socket using a suitable tool.





4.Measure adjusting screw height "H", and loosen lock nut (2).
5.Remove adjusting screw (1), retainer (3) and spring (4) from gear housing assembly (5).

INSPECTION AFTER DISASSEMBLY

Joint Cover
Check joint cover protrusion for damage. Replace if there are.
Rack and Pinion Assembly
- Check pinion assembly for damage or wear. Replace as necessary.
- Rotate pinion assembly and check for torque variation or rattle. Replace steering gear as necessary.
Gear Housing Assembly
Check gear housing assembly for damage or scratches. Replace steering gear as necessary.
Outer Socket and Inner Socket





1.Check ball joint swinging torque.
- Hook Tool at the point shown and pull the spring balance.
Make sure that the spring balance reads the specified value when ball stud and inner socket start to move. Replace outer socket and inner socket if they are outside the standard.










2.Ball joint axial end play





- Apply an axial load of 490 N (50 kg-f, 111 lb-f) to ball stud.
Measure amount of stud movement using a dial gauge, and then make sure that the value is within the specified range.
Replace outer socket and inner socket if the measured value is outside the standard.







ASSEMBLY

1.Apply recommended grease to teeth part and bush part of rack assembly, if necessary.
2.Apply recommended grease to back of rack assembly, if necessary.
3.Install inner socket to rack assembly. Torque to specified value while holding the flat portion of the rack next to the inner socket using a suitable tool.
4.Apply recommended grease to inner socket.





5.Decide on the neutral position for the rack assembly.
Rack stroke "L": Specifications.





6.Apply recommended grease to around retainer (3), then install retainer (3), spring (4) and adjusting screw (1) to gear housing assembly (5).
7.Apply recommended thread locking sealant to the thread (2
turns thread), and then screw in the adjusting screw (1) until it reaches height "H" from gear housing assembly (5) measured before disassembling.
8.Tighten lock nut to (2) the specified torque securing it to prevent adjusting screw (1) from freewheeling condition.
9.Move rack assembly 10 strokes throughout the full stroke so that the parts can fit with each other.





10.Using Tools A and B, measure rotating torque of pinion assembly. If the measurement is outside of the specified range, readjust pinion rotating torque. If the measurement is outside of the specified range for readjust, replace steering gear assembly.

Tool numbers A: ST-3127S000 (J-25742-1)
B: KV-48103400 (-)










11.Set dial gauge to the back of rack assembly on the pinion assembly side around the center of stroke. Measure displacement of rack under torsional torque of ±7.8 Nm (0.80 kg-m, 69 in-lb), and then check if it is within the standard value. If the measurement is outside the standard value, adjust it again. After the readjustment, if measurement is still outside the standard value, replace steering gear assembly.
Standard value: Less than 0.1 mm (0.004 in)
12.Install boot to gear housing assembly and inner socket.





13.Install boot clamp (1) to boot using Tool.
NOTE:
Install large diameter side boot clamp (1) securely to boot groove, and crimp it so as to have clearance of 3 mm (0.12 in) or less as shown.
Tool number: KV-40107300 (-)





14.Install joint cover (1) to gear housing assembly (2).

CAUTION:
Install joint cover so that the protrusion for locating is securely set to gear housing groove.





15.Adjust inner socket to standard length "L", and then tighten lock nut to the specified torque. Check length of inner socket "L"
again after tightening lock nut. Make sure that the length is the standard.
Inner socket length "L": "Socket and Inner Socket"


CAUTION:
Adjust toe-in. Front Suspension. Length achieved after toe-in adjustment is not necessarily the above value.