Disassembly and Assembly
DISASSEMBLYNOTICE: When using a vise, do not overtighten it.
1. REMOVE 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.
2. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the PS gear assembly in a vise.
SST 09612-00012
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.
HINT: Mark the RH and LH tie rod ends and lock nuts.
c. Employ the same manner described above to the other side.
4. REMOVE RH AND LH CLIPS, CLAMPS AND RACK BOOTS
a. Using a screwdriver, 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.
5. REMOVE RH AND LH RACK ENDS
a. Using SST, hold the LH rack end steadily and using another SST, remove the RH rack end.
SST 09922-100010
NOTICE: Use SST 09922-10010 in the direction shown in the illustration.
HINT: Mark the RH and LH rack ends.
b. Using SST, hold the steering rack RH side steadily and using another SST, remove the LH 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.
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 AND RACK GUIDE SUBASSEMBLY
a. Using a hexagon wrench (19 mm), remove the rack guide spring cap.
b. Remove the rack guide spring and rack guide subassembly.
8. REMOVE RACK HOUSING CAP
9. REMOVE SELF-LOCKING NUT
Using SST, stop the control vale shaft rotating and remove the self-locking nut.
SST 09616-00011
10. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Remove the dust seal.
b. Place matchmarks on the control valve housing and rack housing.
c. Remove the 2 bolts.
d. Pull out the control valve housing with control valve assembly.
e. Remove the gasket.
11. REMOVE CONTROL VALVE ASSEMBLY
a. Wind vinyl tape on the control valve shaft.
b. Press out the contra valve assembly.
NOTICE:
^ Be careful not to damage the oil seal lip.
^ Place a shop rag between the valve housing and the blocks.
^ Be careful not to drop the valve assembly.
12. REMOVE OIL SEAL OF CONTROL VALVE ASSEMBLY
Remove the oil seal from the control valve assembly.
13. REMOVE CYLINDER END STOPPER
a. Using needle nose Pliers, remove the snap ring.
b. Pull out the cylinder end stopper.
14. REMOVE STEERING RACK WITH BUSHING
a. Using SST, press out the steering rack with the bushing.
SST 09950-70010 (09951-07200)
NOTICE: Take care not to drop the steering rack.
b. Remove the O-ring from the bushing.
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. REPLACE OIL SEAL OF RACK HOUSING
a. Using SST, press out the oil seal.
SST 09950-60010 (09951-00210, 09951-00240, 09952-06010) 09950-70010 (09951-07360)
NOTICE: Do not damage the rack housing.
b. Coat a new oil seal lip with power steering fluid.
c. Install the oil seal to SST, and press them into the rack housing.
SST 09950-60010 (09951-00210, 09951-00380, 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.
2. REPLACE OIL SEAL AND BEARING OF CONTROL VALVE HOUSING
a. Using SST, press out the bearing and oil seal from the control valve housing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07100)
b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60910 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07100)
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 (09551-00190, 09951-00340, 09952-06010), 09950-70010 (09951-07100)
3. REPLACE NO.1 BEARING OF RACK HOUSING
a. Using a screwdriver and hammer, tap out the No.1 bearing from the rack housing.
b. Coat a new bearing with molybdenum disulfide lithium base grease.
c. Using SST, press in the No.1 bearing.
SST 09950-60010 (09951-00220, 09951-00320, 09951-00420, 09951-00430, 09952-06010), 09950-70010 (09951-07100)
4. REPLACE NO. 2 BEARING OF RACK HOUSING
a. Using SST and a hammer, tap out the No. 2 bearing from the rack housing.
SST 09950-70010 (09951-07100)
b. Coat a new bearing with molybdenum disulfide lithium base grease.
c. Using SST, press in the No. 2 bearing.
SST 09950-60010 (09951-00280, 09951-00420, 09951-00430, 09952-06010), 09950-70010 (09951-07100)
5. REPLACE OIL SEAL OF STALING RACK BUSHING
a. Using SST, remove oil seal from the bushing.
SST 09612-24814 (09613-22011)
NOTICE: Be careful not to damage the bushing.
HINT: As shown in the illustration, from the opposite side of SST confirm that its claws are firmly caught on the oil seal.
b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press it the oil seal.
SST 09950-60010 (09951-00210, 09951-00350, 09952-06010)
NOTICE: Make sure that the oil seal is installed facing in the correct direction.
6. REPLACE TEFLON RING AND D-RING OF STEERING RACK
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 over expand 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. REPLACE TEFLON RINGS OF CONTROL VALVE ASSEMBLY
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 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 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 STEERING RACK
a. Install SST to the rack.
SST 09631-10041
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 09631-10041
3. INSTALL STEERING RACK 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 Into the rack housing.
NOTICE:
^ Make sure that the bushing is installed facing in the correct direction.
^ Be careful not to damage the oil seal lip.
4. INSTALL CYLINDER END STOPPER
a. Push into the cylinder end stopper
b. Using needle nose pliers, install the snap ring.
5. AIR TIGHTNESS TEST
a. Install SST to the rack housing.
SST 09631-12071 (09633-00010)
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.
6. 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 lips.
7. INSTALL OIL SEAL OF CONTROL VALVE ASSEMBLY
a. Coat a new oil seal lip with power steering fluid.
b. Using SST, press in the oil seal.
SST 09612-22011
8. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Install a new gasket.
b. Align the matchmarks on the control valve housing and rack housing.
c. Push into the control valve housing with control valve assembly.
d. Install the 2 bolts.
Torque: 21 Nm (210 kgf-cm, 15 ft. lbs.)
e. install the dust seal.
9. INSTALL SELF-LOCKING NUT
Using SST, stop the control valve shaft rotating and install a new self-locking nut.
SST 09616-00010
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
10. 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 a hammer, stake the 2 parts of the rack housing cap.
11. 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. 08833-00480, THREE BOND 1344, LOCTITE 242 or equivalent
c. Temporarily install the rack guide spring cap.
12. 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 a hexagon wrench (19 mm), torque the rack guide spring cap.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
c. Using a hexagon wrench (19 mm), 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. Using a hexagon wrench (19 mm), loosen the rack guide spring cap until the rack guide spring is not functioning.
f. Using SST, a torque wrench and hexagon wrench (19 mm), tighten the rack guide spring cap until the preload is within the specification.
SST 09616-00010
Preload (turning): 0.8 - 1.3 Nm (8 - 13 kgf-cm, 6.9 - 11.3 inch lbs.)
13. 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 a hexagon wrench (19 mm), hold the rack guide spring cap and using SST, torque the rack guide spring cap lock nut.
SST 09922-10010
Torque: 28 Nm (290 kgf-cm, 21 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 - 1.3 Nm (8 - 13 kgf-cm, 6.9 - 11.3 inch lbs.)
e. Remove the RH and LH rack ends.
14. INSTALL RH AND LH RACK ENDS
a. Temporarily install the LH rack end.
b. Using SST, hold the steering rack RH side steadily and using another SST, torque the LH 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. Temporarily install the RH rack end.
d. Using SST, hold the LH rack end steadily and using another SST, torque the RH 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).
15. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS
a. Ensure that the steering rack end 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 clamp.
NOTICE: Be careful not to damage or twist the 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.
16. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
a. Screw the lock nut tend tie rod end onto the rack end until the matchmarks are aligned.
b. Employ the same manner described above to the other side.
c. After adjusting toe in, torque the nut.
Torque: 47 Nm (480 kgf-cm, 35 ft. lbs.)
17. INSTALL 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: 10 Nm (100 kgf-cm, 7 ft. lbs.)
HINT: Use a torque wrench with a fulcrum length of 250 mm (9.84 inch).