Disassembly and Assembly
DISASSEMBLYNOTICE: 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
Using SST, remove the 2 turn pressure tubes.
SST 09023-38200
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, WIRES AND RACK BOOTS
a. Using needle nose pliers, loosen the wire.
b. Remove the clip, wire and rack boot.
NOTICE: Be careful not to damage the boot.
HINT: Mark the RH and LH rack boots.
c. Employ the same manner described above to the other side.
5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS
a. Using a chisel and a hammer, unstake the washer.
NOTICE: Avoid any impact on the steering rack.
b. Using a spanner, 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.
c. Remove the claw washer.
d. Employ the same manner described above to the other side.
6. REMOVE RACK GUIDE SPRING CAP, CONICAL SPRING WASHER AND RACK GUIDE SUB-ASSEMBLY
7. REMOVE RACK HOUSING CAP
a. Remove the rack housing cap.
b. Remove the O-ring from the rack housing cap.
8. REMOVE CONTROL VALVE ASSEMBLY
Pull out the control valve assembly.
NOTICE: Be careful not to damage the oil seal lip.
9. REMOVE CYLINDER END STOPPER
a. Using snap ring pliers, remove the snap ring.
b. Pull out the cylinder end stopper.
10. REMOVE STEERING RACK AND OIL SEAL
Using SST, press out the steering rack and oil seal.
SST 09950-70010 (09951-07200)
NOTICE: Take care not to drop the steering rack.
11. REMOVE OIL SEAL
Using SST, press out the oil seal.
SST 09950-60010 (09951-00280), 09950-70010 (09951-07360)
NOTICE: Do not damage the rack housing.
INSPECTION
NOTICE: When using a vise, do not overtighten it.
INSPECT STEERING RACK
a. Using a dial indicator, check the rack for runout, teeth wear and damage.
Maximum runout: 0.1 mm (0.004 inch)
b. Check the back surface for wear and damage.
REPLACEMENT
NOTICE: When using a vise, do not overtighten it.
1. IF NECESSARY, REPLACE BEARING
a. Using SST, remove the bearing guide nut and bearing.
SST 09617-35020
Coat a new bearing with molybdenum disulfide lithium base grease.
c. Install the bearing and using SST, install the bearing guide nut.
SST 09617-35020
Torque: 40 Nm (410 kgf-cm, 30 ft. lbs.)
2. IF NECESSARY, REPLACE OIL SEAL
a. Using a screwdriver with vinyl tape wound around its tip, remove the oil seal.
NOTICE: Be careful not to damage the rack housing cap.
b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00210, 09951-00340, 09952-06010), 09950-70010 (09951-07100)
NOTICE: Make sure that the oil seal is installed facing in the correct direction.
3. IF NECESSARY, REPLACE OIL SEAL
a. Using SST, remove the oil seal.
SST 09612-20010
NOTICE: Be careful not to damage the rack housing.
b. Coat a new oil seal lip with power steering fluid.
c. Using SST and a hammer, tap in the oil seal.
SST 09950-60010 (09951-00240, 09951-00350, 09952-06010), 09950-70010 (09951-07150)
NOTICE: Make sure that the oil seal is installed facing in the correct direction.
4. IF NECESSARY, REPLACE BEARING
a. Using a punch and a hammer, tap out the bearing.
b. Coat a new bearing molybdenum disulfide lithium base grease.
c. Using a brass bar and a hammer, tap in the bearing.
5. IF NECESSARY, REPLACE 2 UNION SEATS
a. Using a screw extractor, remove the union seat from the rack housing.
b. Using a hammer and an extension bar, lightly tap in a new union seat.
NOTICE: Before installing the union seat, remove the dust sticking to the rack housing.
c. Employ the same manner described above to the other side.
6. 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 to the steering rack.
c. Expand a new teflon ring with your fingers.
NOTICE: Be careful not to overexpand the teflon 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.
7. 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 rings.
b. Expand 4 new teflon rings with your fingers.
NOTICE: Be careful not to overexpand 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 they 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.
Part 1 Of 3:
Part 2 Of 3:
Part 3 Of 3:
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. Install the oil seal to SST, and press them into the rack housing
SST 09950-60010 (09951-00240, 09951-00400, 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 rack.
SST 09631-20051
HINT: If necessary, scrape the burrs off the rack teeth end and burnish
b. Coat SST with power steering fluid.
c. Install the steering rack into the rack housing
d. Remove the SST.
SST 09631-20051
4. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
c. Install the oil seal by pushing it into the rack housing without tilting.
NOTICE:
^ Make sure that the oil seal is installed facing in the correct direction.
^ Be careful not to damage the oil seal lip.
5. INSTALL CYLINDER END STOPPER
a. Using SST and a hammer, drive in the cylinder end stopper.
SST 09612-22011
Using snap ring pliers, install a new snap ring to the rack housing.
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 a change in the vacuum, check the installation of the oil seals.
7. INSTALL CONTROL VALVE ASSEMBLY
NOTICE: Be careful not to damage the teflon rings and oil seal lips.
8. INSTALL RACK HOUSING CAP
a. Coat a new O-ring with power steering fluid, and install it to the rack housing cap.
b. Install the rack housing cap.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)
9. INSTALL RACK GUIDE SUB-ASSEMBLY, CONICAL SPRING WASHER AND RACK GUIDE SPRING CAP
a. Install the rack guide sub-assembly and conical spring washer.
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.
10. 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. Torque the rack guide spring cap.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
c. Return the rack guide spring cap 12°.
d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00011
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
Preload (turning): 0.9 - 1.3 Nm (9 - 13 kgf-cm, 8.0 - 11.5 inch lbs.)
g. Using a punch and a hammer, stake 2 parts in opposing positions on the rack guide spring cap.
h. Recheck the total preload.
Preload (turning): 0.9 - 1.3 Nm (9 - 13 kgf-cm, 8.0 - 11.5 inch lbs.)
i. Remove the RH and LH rack ends.
11. INSTALL R HAND LH CLAW WASHERS AND RACK ENDS
a. Install a new claw washer, and temporarily install the rack end.
HINT: Align the claws of the claw washer with the steering rack grooves.
b. Using a spanner, hold the steering rack steadily and using SST, torque the rack end.
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: Use a torque wrench with a fulcrum length of 380 mm (14.96 inch).
c. Using a brass bar and a hammer, stake the washer.
NOTICE: Avoid any impact on the steering rack.
d. Employ the same manner described above to the other side.
12. INSTALL RH AND LH RACK BOOTS, WIRES AND CLIPS
a. 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 the steering wheel is turned.
b. Install the boot, clip and a new wire.
NOTICE: Be careful not to damage or twist the boot.
c. After winding and tightening the wire around the circumference of the boot twice, twist it several times, and install it.
d. As shown in the illustration, bend the wire to the circular direction to prevent damage to the boot.
e. Employ the same manner described above to the other side.
13. INSTALL R HAND 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 nut.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)
c. Employ the same manner described above to the other side.
14. INSTALL 2 TURN PRESSURE TUBES
Using SST, install the 2 turn pressure tubes.
SST 09023-38200
Torque: 23 Nm (230 kgf-cm, 17 ft. lbs.)
HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
This torque value is effective in case that SST is parallel to a torque wrench.