Disassembly and Assembly

DISASSEMBLY

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





1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise, as shown in the illustration
SST 09630-00014 (09631-00142)





2. REMOVE 2 TURN PRESSURE TUBES
Using SST, remove the tube SST 09633-00020
3. REMOVE TUBE SUPPORT RETAINER
Remove the bolt





4. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS
Using pliers, loosen the clamp, as shown in the illustration

NOTICE:
^ Be careful not to damage the boot.
^ Mark the RH and LH boots.





5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS
a. Using a screwdriver and hammer, stake back the washer

NOTICE: Avoid and impact to the steering rack.





b. Using a spanner to hold the steering rack steady, and using SST, remove the rack end.
SST 09922-10010

NOTICE:
^ Use SST 09922-10010 in the direction shown in the illustration.
^ Mark the RH and LH rack ends.





6. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
SST 09922-10010

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

7. REMOVE RACK GUIDE SPRING CAP
8. REMOVE RACK GUIDE SPRING AND RACK GUIDE SUBASSEMBLY
9. REMOVE DUST COVER





10. REMOVE CONTROL VALVE HOSING WITH CONTROL VALVE ASSEMBLY
a. Place matchmarks on the valve housing and rack housing.
b. Remove the 2 bolts.
c. Pull out the control valve assembly with the valve housing.
d. Remove the O-ring from the valve housing.
11. REMOVE CONTROL VALVE ASSEMBLY





a. Using SST, loosen the bearing guide nut.
SST 09631-20060





b. Wind vinyl tape to the control valve shaft.
c. Using a plastic hammer, tap out the valve assembly with the nut from the control valve housing.

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

d. Remove the nut from the valve assembly.

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

e. Remove the O-ring from the nut.





12. REMOVE CYLINDER END STOPPER AND SPACER
a. Using SST, remove the stopper.
SST 09922-10010

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

b. Remove the O-ring from the stopper.





13. REMOVE STEERING RACK AND OIL SEAL
a. Using SST, press out the rack and oil seal.

NOTICE: Take care not to drop the rack.

SST 09950-70010 (09951-07200)
b. Remove the oil seal from the rack.





14. REMOVE OIL SEAL AND SPACER
Using SST, press out the oil seal and spacer.
SST 09950-60010 (09951-00360), 09950-70010 (09951-07360)


INSPECTION





1. INSPECT STEERING RACK
a. Using a dial indicator, check the rack for runout and for teeth wear and damage.
Maximum runout: 0.03 mm (0.0118 inch)
b. Check the back surface for wear and damage.
2. 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 (09951-00260), 09950-70010 (09951-07150)





b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00330, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Make sure to install the oil seal facing the correct direction.





d. Coat a new bearing with molybdenum disulfide lithium base grease.
e. Using SST, press in the bearing.
SST 09950-00010 (09951-00330), 09957-00010 (09951-07150)
3. IF NECESSARY, REPLACE OIL SEAL





a. Using SST, press out the oil seal from the bearing guide nut.
SST 09950-00010 (09951-00320), 09950-70010 (09951-07100)





b. Coat a new oil seat lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00280, 09951-00360, 09952-06010), 09957-00010 (09951-07100)

NOTICE: Make sure to install the oil seal facing the correct direction.





4. INSPECT BEARING
a. Check the needle roller bearing of the rack housing for pitmarks or damage.
If faulty, replace the rack housing,
b. Coat the inside of the bearing with molybdenum disulfide lithium base grease.





5. INSPECT BEARING
a. Check the bearing rotation condition and check for abnormal noise.
If the bearing is worn or damaged, replace the control valve assembly.
b. Coat the bearing with molybdenum disulfide lithium base grease.





6. INSPECT BUSHING
a. Check the inside of the bushing of the cylinder end stopper for cracks. If faulty, replace the bushing.
b. Apply molybdenum disulfide lithium base grease to the inside of the bushing.





7. IF NECESSARY, REPLACE BUSHING
a. Using a screwdriver, remove the bushing from the cylinder end stopper.

NOTICE: Be careful not to damage the cylinder end stopper.

b. Coat the inside of a new bushing with molybdenum disulfide lithium base grease.
c. Install the bushing.
8. 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 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 overexpand the ring.





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





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

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

b. Expand 4 new rings with your fingers.

NOTICE: Be careful not to overexpand the ring.

c. Coat the rings with power steering fluid.





d. Install the rings to the control valve assembly, and settle them down with your fingers.
e. Carefully slide the tapered end of SST over the rings until the ring fits to the steering rack.
SST 09631-20081

NOTICE: Be careful not to damage the rings.

10. IF NECESSARY, REPLACE UNION SEAT





a. Using a screw extractor, remove the seat from the control valve housing.





b. Using plastic hammer and sliding handle, lightly tap in a new seat.

NOTICE: Before installing the union seat, remove dust sticking to the control valve housing.


REASSEMBLY

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

1. COAT WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE





2. INSTALL SPACER AND OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST, press in the oil seal and spacer.
SST 09951-60010 (09951-00350, 09951-00550, 09952-06010), 09957-00010 (09951-07360)

NOTICE:
^ Make sure to install the oil seal facing 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 09631-00350

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

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





4. INSTALL OIL SEAL
a. Install SST to the steering rack opposite end.
SST 09631-00350
b. Coat SST with power steering fluid.
c. Coat a new oil seal lip with power steering fluid.
d. Install the oil seal by pushing it onto the SST without tilting.

NOTICE: Make sure to install the oil seal facing the correct direction.

e. Remove the SST.
5. INSTALL SPACER AND CYLINDER END STOPPER
a. Install the spacer.
b. Coat a new O-ring with power steering fluid, and install it to the stopper.





c. Using a wooden block and hammer, drive in the stopper until it is tightly installed.

NOTICE: Be careful not to damage the ring.





d. Using SST, torque the stopper.
SST 09922-10010
Torque: 66 Nm (677 kgf-cm, 49 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).





6. AIR TIGHTNESS TEST
a. Install SST to the unions of the rack housing.
SST 09631-12071
b. Apply 53 kPa (400 mmHg,15.75 in.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 CONTROL VALVE ASSEMBLY
a. Coat the teflon rings with power steering fluid.





b. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
c. Push the valve assembly into the control valve housing.

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





d. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.
e. Using SST, torque the nut.
SST 09631-20060
Torque: 25 Nm (250 kgf-cm,18 ft. lbs.)

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





f. Using a punch, stake the nut.
8. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Coat a new O-ring with power steering fluid, and install it to the valve housing.
b. Align the matchmarks on the valve housing and rack housing, and install the valve housing with the valve assembly to the rack housing.
c. Torque the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
9. INSTALL DUST COVER
10. INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
a. Apply sealant to 2 or 3 threads of the cap.
Sealant: Part No. 08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Temporarily install the cap.
11. 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 cap 19°.





d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00010
e. Loosen the cap until the rack guide spring is not functioning.





f. Using SST and a torque wrench, tighten the cap until the preload is within specification.
SST 09616-00010
Preload (turning): 1.3 - 1.8 Nm (13.18.4 kgf-cm, 11.5 - 16.0 inch lbs.)





12. INSTALL RACK GUIDE SPRING CAP LOCK NUT
a. Apply sealant to 2 or 3 threads of the nut.
Sealant: Part No.088300080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Holding the rack guide spring cap rotating, and using SST, torque the nut.
SST 09922-10010
Torque: 51 Nm (521 kgf-cm, 38 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): 1.3 - 1.8 Nm (13.18.4 kgf-cm, 11.0 - 16.0 inch lbs.)
d. Remove the RH and LH rack ends.
13. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS





a. Install a new washer, and temporarily tighten the rack end.

HINT: Align the claws of the washer with the steering rack grooves.





b. Using a spanner to hold the steering rack steady, and using SST, torque the rack end.
SST 09922-10010
Torque: 76 Nm (770 kgf-cm, 56 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 washer.

NOTICE: Avoid any impact to the rack.

14. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS





a. Ensure that the tube hole is not clogged with grease.

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





b. Install the boot.

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

c. Using pliers tighten a new clamp, as shown in the illustration.
15. INSTALL TUBE SUPPORT RETAINER
Torque the bolt.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)





16. INSTALL 2 TURN PRESSURE TUBES
Using SST, install the tube.
SST 09630-00020
Torque: 20 Nm (203 kgf-cm, 15 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