Disassembly and Assembly

Part 1 Of 2:

Part 2 Of 2:

DISASSEMBLY

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





1. SECURE MANUAL STEERING GEAR ASSEMBLY IN VISE
Using SST, secure the manual steering gear assembly in a vise.
SST 09612-00012





2. 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.





3. REMOVE RH AND LH CLIPS, CLAMPS AND RACK BOOTS
a. Using pliers, loosen the clamp.
b. Remove the clip, clamp 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.
4. REMOVE RH AND LH RACK ENDS





a. Using SST, hold the steering rack steadily and using another 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.

b. Employ the same manner described above to the other side.





5. 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.

6. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING SPACER, CONICAL SPRING WASHER, RACK GUIDE SPRING AND RACK GUIDE SU8-ASSEMBLY





7. REMOVE OIL SEAL, SPACER AND STEERING PINION
a. Using a screwdriver with vinyl tape wound around its tip, remove the oil seal.

NOTICE: Be careful not to damage the rack housing.

b. Remove the spacer.
c. Using snap ring pliers, remove the snap ring and pull out the steering pinion.

NOTICE: Be careful not to damage the serrations.

8. REMOVE STEERING RACK

NOTICE: To avoid damaging the bushing, remove the rack from the steering pinion housing side of the rack housing without revolving it.

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: 0.15 mm (0.0059 inch)
b. Check the back surface for wear and damage.

REASSEMBLY

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

1. COAT PARTS INDICATED BY ARROWS WITH MOLYBDENUM DISULFIDE LITHIUM BASE GREASE
2. INSTALL STEERING RACK

NOTICE: To avoid damaging the bushing, install the rack from the steering pinion side of the rack housing without revolving it.

3. INSTALL STEERING PINION, SPACER AND OIL SEAL
a. Set the notched side of the steering rack so that the pinion can be positioned inside.
b. Push in the steering pinion, and using snap ring pliers, install the snap ring.

NOTICE: Be careful not to damage the serrations.

c. Install the spacer.
d. Coat a new oil seal lip with molybdenum disulfide lithium base grease.





e. Using SST and a hammer, tap in the oil seal.
SST 09517-12010
4. INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING, CONICAL SPRING WASHER, RACK GUIDE SPRING SPACER AND RACK GUIDE SPRING CAP





a. Install the rack guide sub-assembly, rack guide spring, conical spring washer and rack guide spring spacer.

NOTICE: Make sure that the conical spring washer is installed facing in the correct direction.

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.
5. ADJUST TOTAL PRELOAD
a. Temporarily install the RH and LH rack ends.
b. Torque the rack guide spring cap.
Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.)





c. Using SST, turn the pinion shaft right and left 1 or 2 times.
SST 09612-24014 (09616-10010)
d. Loosen the rack guide spring cap until the rack guide spring is not functioning.





e. Using SST and a torque wrench, tighten the rack guide spring cap until the preload is within specification.
SST 09612-24014 (09616-10010)
Preload (turning): 0.6 - 1.5 Nm (6 - 15 kgf-cm, 5.2 - 13.0 inch lbs.)





6. 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. Hold the rack guide spring cap rotating and using SST, torque the rack guide spring cap lock nut.
SST 09922-10010
Torque: 36 Nm (365 kgf-cm, 26 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. Recheck the total preload.
Preload (turning): 0.6 - 1.5 Nm (6 - 15 kgf-cm, 5.2 - 13.0 inch lbs.)
d. Remove the RH and LH rack ends.
7. INSTALL RH AND LH RACK ENDS





a. Using SST, hold the steering rack steadily and using another SST, install 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).

b. Employ the same manner described above to the other side.
8. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS
a. Install the rack boot, clip and a new clamp.

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





b. After winding and tightening the clamp around the circumference of the boot twice, twist it several times, and install it.





9. 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: 47 Nm (480 kgf-cm, 35 ft. lbs.)
c. Employ the same manner described above to the other side.