Disassembly and Assembly

Part 1 Of 3:

Part 2 Of 3:

Part 3 Of 3:

DISASSEMBLY

NOTICE: When using a vise, do not overtighten it.





1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the PS gear assembly in a vise.
SST 09612-00012
2. REMOVE 2 TURN PRESSURE TUBES





a. Using SST, remove the 2 turn pressure tubes.
SST 09023-38200
b. Remove the 4 O-rings from the 2 turn pressure tubes.





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, and remove the tie rod end and lock nut.
c. Employ the same manner described above to the other side.





4. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS
a. Using a screwdriver, loosen the clamp.

NOTICE: Be careful not to damage the rack boot.

b. Remove the clip and rack boot.
c. Employ the same manner described above to the other side.

HINT: Mark the RH and LH rack boot.

5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS





a. Using a screwdriver and hammer, unstake the claw washer.

NOTICE: Avoid any impact on the steering rack.





b. Using a spanner (24 mm) 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.
c. Remove the claw washer.
d. Employ the same manner described above to the other side.

HINT: Mark the RH and LH rack ends.





6. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the rack guide spring cap lock nut.
SST 09922-10010

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

7. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING, RACK GUIDE SUB-ASSEMBLY





a. Using SST, remove the rack guide spring cap.
SST 09631-10021
b. Remove the rack guide spring and rack guide sub-assembly.
8. REMOVE RACK HOUSING CAP





9. REMOVE SELF-LOCKING NUT
Using SST, stop the control valve shaft rotating and remove the self-locking nut.
SST 09616-00011
10. REMOVE DUST SEAL





11. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place matchmarks on the control valve housing and rack housing.
b. Remove the 2 bolts and control valve housing.
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 control valve shaft.
b. Press out the control valve assembly with the oil seal.

NOTICE:
^ 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 RACK HOUSING NO. 2 GROMMET





a. Place matchmarks on the rack housing No. 2 bracket and rack housing.





b. Using a screwdriver, pry the clamp of the rack housing No. 2 bracket and remove the rack housing No. 2 bracket.
c. Remove the rack housing No. 2 grommet from the rack housing No. 2 bracket.
15. REMOVE CYLINDER END STOPPER





a. Using SST, turn the cylinder end stopper clockwise until the wire end is visible through the service hole.
SST 09631-10021
b. Using SST, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper.
SST 09631-10021





16. REMOVE STEERING RACK AND BUSHING
a. Using a brass bar and hammer, tap out the steering rack with the bushing.
b. Remove the bushing from the steering rack.
c. Remove the O-ring from the bushing.





17. REMOVE OIL SEAL
Using SST, press out the oil seal.
SST 09950-60010 (09951-00290), 09950-70010 (09951-07360)

INSPECTION

NOTICE: When using a vise, do not overtighten it.

INSPECT STEERING RACK





a. Using a dial indicator, check the steering rack for runout and for teeth wear and damage.
Maximum runout: 0.03 mm (0.0012 inch)
b. Check the back surface for wear and damage.

REPLACEMENT

NOTICE: When using a vise, do not over tighten it.

1. IF NECESSARY, REPLACE OIL SEAL AND BEARING





a. Using SST, press out the oil seal and bearing from the control valve housing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07200)
b. Coat a new oil seal lip with power steering fluid.





c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07200)

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

d. Coat a new bearing with molybdenum disulfide lithium base grease.





e. Using SST, press in the bearing.
SST 09950-60010 (09951-00180, 09951-00340, 09952-06010), 09950-70010 (09951-07200)
2. IF NECESSARY, REPLACE 2 BEARINGS





a. Using a brass bar and hammer, tap out the bearing from the rack housing.





b. Using SST, press out the bearing from the rack housing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07200)
c. Coat a new bearing with molybdenum disulfide lithium base grease.





d. Using SST, press in the bearing.
SST 09950-60010 (09951-00250, 09951-00310, 09952-06010), 09950-70010 (09951-07200)





e. Coat a new bearing with molybdenum disulfide lithium base grease. Using SST, press in the bearing.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07200)
3. IF NECESSARY, REPLACE OIL SEAL





a. Using SST, remove the oil seal from the bushing.
SST 09527-20011, 09612-24014 (09613-22011)

NOTICE: Be careful not to damage the bushing.

b. Coat a new oil seal lip with power steering fluid.





c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00240, 09951-00400, 09952-06010)

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

4. IF NECESSARY, REPLACE TEFLON RING AND O-RING





a. Using a screwdriver, remove the Teflon ring and O-ring from the steering rack.

NOTICE: 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.

NOTICE: Be careful not to over expand the ring.





d. Coat the Teflon ring with power steering fluid.
e. Install the Teflon ring to the steering rack, and settle it down with your fingers.
5. IF NECESSARY, REPLACE 4 TEFLON RINGS





a. Using a screwdriver, remove the 4 Teflon rings from the control valve assembly.

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

b. Expand 4 new Teflon rings with your fingers.

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

c. Coat the Teflon rings with power steering fluid.
d. Install the Teflon rings to the control valve assembly, and settle them down with your fingers.





e. Carefully slide the tapered end of SST over the Teflon rings until the Teflon rings fit to the control valve assembly.
SST 09631-20081

NOTICE: Be careful not to damage the Teflon rings.

REASSEMBLY

NOTICE: When using a vise, do not overtighten it.

1. COAT PARTS INDICATED BY ARROWS 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 SST, press in the oil seal
SST 09950-60010 (09951-00240, 09951-00430, 09952-06010), 09950-70010 (09951-07360)

NOTICE:
^ Make sure that the oil seal is installed facing in the correct direction.
^ Take care that the oil seal does not get reversed as you install it.





3. INSTALL STEERING RACK
a. Install SST to the steering rack
SST 09631-33010

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

b. Coat the SST with power steering fluid
c. Install the steering rack into the rack housing

NOTICE: Be careful not to damage the oil seal lip.

d. Remove SST
SST 09631-33010





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

NOTICE:
^ Make sure that the bushing is installed facing in 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 cylinder end stopper with the slot of the rack housing.
b. Install a new wire into the cylinder end stopper.





c. Using SST, turn the cylinder end stopper clockwise 450 ± 50°.
SST 09631-10021
6. AIR TIGHTNESS TEST
a. Install SST to the rack housing.
SST 09631-12071





b. Apply 53 kPa (400 mm Hg, 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 RACK HOSING NO. 2 GROMMET





a. Install the rack housing No. 2 grommet to the rack housing No. 2 bracket.

HINT: Align the projection of the rack housing No. 2 grommet with the hole of the rack housing No. 2 bracket.

b. Align the matchmarks on the rack housing No. 2 bracket and rack housing.





c. Place the rack housing No. 2 bracket in a vise and install the vise to fasten the clamp.





8. INSTALL CONTROL VALVE ASSEMBLY
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
b. Coat the Teflon rings with power steering fluid.
c. Install the control valve assembly into the control valve housing.

NOTICE: Be careful not to damage the Teflon rings and oil seal.

9. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid.





b. Using SST, press in the oil seal.
SST 09612-22011

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

10. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place a new gasket on the rack housing.
b. Align the matchmarks on the control valve housing and rack housing.
c. Install the 2 bolts.
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)





11. INSTALL SELF-LOCKING NUT
Using SST, stop the control valve shaft rotating and install a new self-locking nut.
SST 09616-00011
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
12. INSTALL DUST SEAL





13. INSTALL RACK HOUSING CAP
a. Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Install the rack housing cap.
Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.)
c. Using a punch and hammer, stake the 2 parts of the rack housing cap.
14. INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
a. Install the rack guide sub-assembly and rack guide spring.
b. 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
c. Temporarily install the rack guide spring cap.
15. ADJUST TOTAL PRELOAD
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.





b. Using SST, torque the rack guide spring cap.
SST 09631-10021
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





c. Using SST, return the rack guide spring cap 12°.
SST 09631-10021





d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00011
e. Using SST, loosen the rack guide spring cap until the rack guide spring is not functioning.
SST 09631-10021





f. Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification.
SST 09616-00011, 09631-10021
Preload (turning): 0.8 - 1.4 Nm (8 - 14 kgf-cm, 6.9 - 12.2 inch lbs.)
16. INSTALL RACK GUIDE SPRING CAP LOCK NUT
a. 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
b. Temporarily install the rack guide spring cap lock nut.





c. Using SST, hold the rack guide spring cap and using another SST torque the rack guide spring cap lock nut.
SST 09631-10021, 09922-10010
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)

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

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

d. Recheck the total preload.
Preload (turning): 0.8 - 1.4 Nm (8 - 14 kgf-cm, 6.9 - 12.2 inch lbs.)
e. Remove the RH and LH rack ends.
17. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS





a. Install a new claw washer, and temporarily install the rack ends.

HINT: Align the claws of the claw washers with the steering rack grooves.





b. Using a spanner (24 mm), hold the steering rack steadily and using SST, torque the rack end.
SST 09922-10010
Torque: 60 Nm (610 kgf-cm, 44 ft. lbs.)

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

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





c. Using a brass bar and hammer, stake the claw washer.

NOTICE: Avoid any impact on the steering rack.

d. Employ the same manner described above to the other side.
18. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS





a. Ensure that the steering rack hole is not clogged with grease.

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





b. Install the rack boot, clip and a new clamp.

NOTICE: Be careful not to damage or twist the rack boot.

c. Using SST, tighten the clamp as shown in the illustration.
SST 09521-24010
d. Employ the same manner described above to the other side.





19. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
b. After adjusting toe-in, torque the lock nut.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)
c. Employ the same manner described above to the other side.
20. INSTALL 2 TURN PRESSURE TUBES
a. Coat 4 new O-rings with power steering fluid and install them to the 2 turn pressure tubes.





b. Using SST, install the 2 turn pressure tubes.
SST 09023-38200
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)

HINT: Use a torque wrench with a fulcrum length of 250 mm (9.84 inch).

This torque value is effective in case that SST is parallel to a torque wrench.