Overhaul
Steering GearboxDISASSEMBLY
RACK HOUSING ASSEMBLY
1) Disconnect the four pipes from gearbox.
NOTE:
Remove the pipes C and D, which are fixed to clamp plate, as a unit.
2) Secure the gearbox removed from vehicle in a vise using ST.
CAUTION:
Secure the gearbox in a vise using ST as shown in the figure. Do not secure the gearbox without this ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
3) Remove the tie-rod end and lock nut from gearbox.
4) Remove the small clip from the boot using pliers, and then move the boot to tie-rod end side.
5) Using a flat tip screwdriver, remove the band from boot.
NOTE:
Replace the boot if there is damage, cracks or deterioration.
6) Using the ST, loosen the lock nut.
ST 926230000 SPANNER
7) Tighten the adjusting screw until it can no longer be tightened.
8) Remove the tie-rod.
9) Loosen the adjusting screw, and remove the spring and sleeve.
10) Remove the two bolts securing valve assembly.
11) Carefully draw out the input shaft and remove the valve assembly.
12) Using a drill, release the crimping of holder.
CAUTION:
Make a hole of 2 mm (0.08 in) depth using a drill with 3 mm (0.12 in) diameter.
13) Remove the holder.
14) Attach the ST to the pinion housing side of the rack, and push out the rack together with the outer side oil seal.
ST 34199FE000 INSTALLER & REMOVER
NOTE:
Block the pipe connection of steering body to prevent fluid from flowing out.
15) Insert the ST from pinion housing side and remove the oil seal using a press.
ST 34099PA010 OIL SEAL REMOVER
16) Using a press, remove the bushing of gearbox installation portion.
CONTROL VALVE
1) Disconnect the pipes A and B from gearbox.
2) Secure the gearbox removed from vehicle in a vise using ST.
CAUTION:
Secure the gearbox in a vise using ST as shown in the figure. Do not secure the gearbox without this ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
3) Using the ST, loosen the lock nut.
ST 926230000 SPANNER
4) Loosen the adjusting screw, and remove the spring and sleeve.
5) Remove the two bolts securing valve assembly.
6) Carefully draw out the input shaft and remove the valve assembly.
7) Put a vinyl tape around the spline portion, and slide the dust cover to remove.
8) Using a press, remove the pinion & valve assembly from valve housing.
9) Using the ST and a press, remove the bushing and oil seal from the valve housing.
CAUTION:
^ Do not apply a force to the end surface of valve housing.
^ Do not reuse the oil seal after removal.
ST 34199AG090 INSTALLER & REMOVER
10) Using a snap ring pliers, remove the snap ring, valve, oil seal and back-up washer.
CAUTION:
Be careful not to scratch the pinion and valve assembly.
ASSEMBLY
RACK HOUSING ASSEMBLY
1) Using a press, install the bushing to gearbox installation portion.
2) Insert the ST to rack.
ST 34199AG040 GUIDE
3) Install the seal ring and O-ring to piston portion of rack.
4) Using the ST, form the seal ring properly.
ST1 34199AG080 FORMER PISTON
ST2 34199AG060 GUIDE G (26)
5) Using the ST A and ST B, attach the oil seal to ST C.
ST 34199FE040 INSTALLER A, B, C
^ INSTALLER A: 34199FE070
^ INSTALLER B: 34199FE080
^ INSTALLER C: 34199FE090
NOTE:
Face the oil seal in the direction as shown in the figure.
6) Insert the ST C with oil seal assembled from the gear side of rack. Remove the oil seal from ST C near piston, and then remove the ST C from rack.
7) Install the back-up washer from the gear side of rack.
8) Check the threaded end of holder and gearbox cylinder end for burrs, damage, etc. Correct if faulty.
9) Apply a coat of grease to the grooves in rack, sliding surface of sleeve and sealing surface of piston. Then insert the rack into steering body from cylinder side.
10) Temporarily tighten a new holder to the gearbox cylinder.
11) Put a mark at the specified position measured from the end surface of ST, as shown in the figure.
Specified position:
12.7 mm (0.5 in)
ST 34199FE000 INSTALLER & REMOVER
12) Set the ST to the end of rack.
ST 34199FE000 INSTALLER & REMOVER
13) Using a press, press-fit until the mark on the ST is aligned with the end surface of the holder.
14) Remove the ST and holder.
15) Insert the outer side oil seal into the rack using the same procedure as steps 5) and 6).
ST 34199FE040 INSTALLER A, B, C
^ INSTALLER A: 34199FE070
^ INSTALLER B: 34199FE080
^ INSTALLER C: 34199FE090
16) Put the ST and pipe through the rack, and press-fit the outer side oil seal using a press.
ST 34199AG010 INSTALLER
17) Secure the gearbox in a vise using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
18) Tighten the holder.
Tightening torque:
70 Nm (7.1 kgf-m, 51.6 ft-lb)
19) Using the ST, crimp so that the diameter of punch hole is 2 - 2.5 mm (0.08 - 0.10 in) and is aligned to the position of 2 mm (0.08 in) from gearbox cylinder end surface.
ST1 34099FA060 PUNCH HOLDER
ST2 34199FE020 BASE
20) Put a vinyl tape around the spline portion and apply genuine grease to the dust cover and install to valve assembly.
CAUTION:
Be sure to install the dust cover to groove of shaft.
21) Apply the genuine grease to the pinion gear and bearing of valve assembly.
22) Install new O-ring to valve assembly. Insert the valve assembly into place while facing the rack teeth toward pinion.
23) Tighten the bolts alternately to secure the valve assembly.
CAUTION:
Be sure to alternately tighten the bolts.
Tightening torque:
20 Nm (2.0 kgf-m, 14.8 ft-lb)
24) Temporarily tighten the tie-rod to the rack end, and then operate the rack from lock to lock for two or three times to make it fit in.
CAUTION:
Operating the rack from lock to lock without installing tie-rods may damage the oil seal. Always install the left and right tie-rods.
25) Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.
Liquid gasket:
THREE BOND 1102 or THREE BOND 1215
26) Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert the sleeve into steering body.
Charge the adjusting screw with grease, and then insert the spring into adjusting screw. Then install on the steering body.
27) Tighten the adjusting screw to the specified torque, then loosen it.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
28) Tighten the adjusting screw to the specified torque, then loosen it within 20°.
Tightening torque:
3.9 Nm (0.4 kgf-m, 2.9 ft-lb)
29) Remove the tie-rod.
30) Adjust the turning resistance of gearbox so that it is within specification using adjusting screw.
31) Attach the lock nut into adjusting screw, and while holding the adjusting screw with wrench, tighten the lock nut using ST.
ST 926230000 SPANNER
Tightening torque (lock nut):
25 Nm (2.5 kgf-m, 18.4 ft-lb)
NOTE:
Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
32) Extend the rack approx. 40 mm (1.57 in) from steering body.
33) Install the tie-rod and new lock washer into rack.
Tightening torque:
90 Nm (9.2 kgf-m, 66.4 ft-lb)
34) Bend the lock washer and crimp it.
CAUTION:
Be careful not to scratch the rack when crimping lock washer.
35) Apply a coat of grease to the tie-rod groove, and then install the boot to the housing.
CAUTION:
Right side boot has groove for identification, be sure to install the right and left of boot.
NOTE:
Make sure that the boot is installed without unusual inflation or deflation.
36) Install a new boot band. Using band clamp pliers, crimp it so that the clearance of crimping portion becomes 2 mm (0.079 in) or less.
37) Fix the boot end with small clip.
38) After installing, check that the boot end is installed to the groove of the tie-rod.
39) If the tie-rod end has been removed, screw in lock nut and tie-rod end to the screwed portion of tie-rod, and tighten the lock nut temporarily in a position as shown in the figure.
Installed tie-rod length L:
29 mm (1.14 in)
40) Inspect the gearbox as follows:
"A" Holding the tie-rod end, repeat lock to lock several times as quickly as possible.
"B" Holding the tie-rod end, turn it slowly at a radius several times as large as possible.
Finally, make sure that the boot is installed in the specified position without inflating.
41) Remove the gearbox from ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
42) Install the four pipes on gearbox.
(1) Connect the pipes A and B to the four pipe joints of gearbox.
Tightening torque:
Refer to "COMPONENT" of "General Description". Specifications
(2) Connect the feed pipe and return pipe to the gearbox.
Tightening torque:
Feed pipe: 37 Nm (3.8 kgf-m, 27.3 ft-lb)
Return pipe: 29 Nm (3.0 kgf-m, 21.4 ft-lb)
CONTROL VALVE ASSEMBLY
Specified steering grease:
VALIANT GREASE M2
1) Clean all parts and tools before reassembling.
2) Apply a coat of specified power steering fluid to the inner wall of valve housing.
3) Apply grease to the oil seal.
4) Verify the direction of oil seal.
5) Using the ST and a press, install the oil seal and the bushing in valve housing.
ST 34199AG090 INSTALLER & REMOVER
6) Apply vinyl tape to the groove of pinion.
7) Install the wave washer and oil seal to pinion, and then remove the vinyl tape.
8) Attach the ST to pinion, and install the seal ring and O-ring.
ST 34199AG020 GUIDE
9) Remove the ST GUIDE, and form the seal ring properly using ST FORMER.
ST 34199AG070 FORMER
10) Put vinyl tape around pinion shaft spline to protect oil seal from damage.
11) Install the valve to pinion, and install the snap ring.
12) Attach the pinion & valve assembly into the valve housing.
13) Using a press, push the outer race of bearing and press-fit the pinion & valve assembly into housing.
14) Apply the specified grease to dust cover.
15) Install the dust cover on valve assembly.
CAUTION:
Be sure to install the dust cover to groove of shaft.
16) Apply the genuine grease to the pinion gear and bearing of valve assembly.
17) Install new O-ring to valve assembly.
18) Insert the valve assembly into place while facing the rack teeth toward pinion.
19) Tighten the bolts alternately to secure the valve assembly.
CAUTION:
Be sure to alternately tighten the bolts.
Tightening torque:
20 Nm (2.0 kgf-m, 14.8 ft-lb)
20) Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.
Liquid gasket:
THREE BOND 1102 or THREE BOND 1215
21) Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert the sleeve into steering body.
Charge the adjusting screw with grease, and then insert the spring into adjusting screw. Then install on the steering body.
22) Tighten the adjusting screw to the specified torque, then loosen it.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
23) Tighten the adjusting screw to the specified torque, then loosen it within 20°.
Tightening torque:
3.9 Nm (0.4 kgf-m, 2.9 ft-lb)
24) Adjust the turning resistance of gearbox so that it is within specification using adjusting screw.
25) Attach the lock nut into adjusting screw, and while holding the adjusting screw with wrench, tighten the lock nut using ST.
ST 926230000 SPANNER
Tightening torque (lock nut):
25 Nm (2.5 kgf-m, 18.4 ft-lb)
NOTE:
Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
26) Remove the gearbox from ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
27) Install the four pipes on gearbox.
(1) Connect the pipes A and B to gearbox.
Tightening torque:
Refer to "COMPONENT" of "General Description". Specifications
(2) Connect the feed pipe and return pipe to the gearbox.
Tightening torque:
Feed pipe: 37 Nm (3.8 kgf-m, 27.3 ft-lb)
Return pipe: 29 Nm (3.0 kgf-m, 21.4 ft-lb)
INSPECTION
BASIC INSPECTION
1) Clean all the disassembled parts, and check for wear, damage or any other faults, then repair or replace as necessary.
2) When disassembling, check the inside of gearbox for water. If any water is found, carefully check the boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts.
SERVICE LIMIT
Make a measurements as follows. If it exceeds the specified service limits, adjust or replace.
NOTE:
When making a measurement, vise the gearbox using ST. Never vise the gearbox by inserting aluminum plates etc. between vise and gearbox.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
Rack shaft sliding resistance:
Limit
343 N (35 kgf, 77 lbf) or less
Left/right differential of sliding resistance:
20% or less
RACK SHAFT PLAY IN THE RADIAL DIRECTION
Right-turn steering:
Service limit
0.12 mm (0.005 in) or less
Condition
Weighting point
L1: 10 mm (0.39 in)
P: 98 N (10 kgf, 22 lb)
Measuring point
L2: 25 mm (0.98 in)
Left-turn steering:
Service limit
Direction white arrows
0.3 mm (0.012 in) or less
Direction black arrows
0.15 mm (0.0059 in) or less
Condition
L: 5 mm (0.20 in)
P: 98 N (10 kgf, 22 lbf)
INPUT SHAFT PLAY
In radial direction:
Service limit
0.26 mm (0.01 in) or less
Condition
P: 98 N (10 kgf, 22 lb)
In axial direction:
Without play
TURNING RESISTANCE OF GEARBOX
Using the ST, measure the gearbox turning resistance.
ST 34099PA100 SPANNER
Service limit:
Maximum allowable resistance:
18 N (1.8 kgf, 4.0 lb) or less
Difference between right and left turning resistance:
24% or less
OIL LEAKAGE
1) Lift up the vehicle.
2) If a fluid leak is found, clean the fluid completely from the suspect area, and turn the steering wheel 30 to 40 times to the left and right from lock to lock, with the engine running, and check again for leaks immediately, and also after a few hours have passed.
3) Cause and solution for oil leakage from "a"
The oil seal is damaged. Replace the valve assembly or valve housing side oil seal with a new part.
4) Cause and solution for oil leakage from "b"
The torsion bar O-ring is damaged. Replace the valve assembly with a new part.
5) Cause and solution for oil leakage from "c"
The oil seal is damaged. Replace the valve assembly or pinion side oil seal with a new part.
6) Cause and solution for oil leakage from "d"
The pipe is damaged. Replace the faulty pipe or O-ring.
7) Cause and solution for oil leakage from "g".
The hose is damaged. Replace the hose with a new part.
8) If leak is other than a, b, c, d or g, or if oil is leaking from gearbox, move the right and left boots toward tie-rod end side, respectively, with the gearbox mounted to the vehicle, and remove fluid from surrounding portions. Then, turn the steering wheel from lock to lock about 30 to 40 times with the engine running, then reinspect the leaking area immediately after and several hours after this operation.
(1) Leakage from "e"
The cylinder seal is damaged. Replace the oil seal.
(2) Leakage from "f"
There are two possible causes. Perform the following step first. Remove the pipe assembly B from the valve housing, and close the circuit using ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock approx. 30 to 40 times with the engine running, then inspect the leaked portion immediately after and several hours after this operation.
^ If leakage from "f" is noted again:
The oil seal of pinion and valve assembly is damaged. Replace the pinion & valve assembly with a new part. Or, replace the oil seal.
^ If oil stops leaking from "f":
The oil seal of rack housing is damaged. Replace the oil seal and back-up washer.