Steering Gear: Service and Repair

POWER STEERING GEAR

Components:

REMOVAL

NOTICE: Remove the steering wheel assembly before the steering gear removal, because there is possibility of breaking of the spiral cable.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3. REMOVE STEERING WHEEL PAD
4. REMOVE STEERING WHEEL ASSEMBLY
5. REMOVE NO. 1 ENGINE UNDER COVER
a. Remove the 7 bolts.
6. REMOVE NO. 2 ENGINE UNDER COVER
a. Remove the 6 bolts.
7. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
8. DISCONNECT TIE ROD END SUB-ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

9. REMOVE ENGINE OIL FILTER ASSEMBLY
a. Disconnect the 2 clips and hoses.
b. Remove the 2 bolts and nut with the bracket.
c. Remove the O-ring.
10. DISCONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY

HINT: Turn the steering wheel fully to the right side.

11. DISCONNECT PRESSURE FEED TUBE ASSEMBLY
a. Remove the union bolt, gasket and disconnect the pressure feed tube.

12. DISCONNECT RETURN TUBE ASSEMBLY
a. Using SST, disconnect the tube.
SST 09023-38401

13. REMOVE TIE ROD END SUB-ASSEMBLY LH
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.
14. REMOVE TIE ROD END SUB-ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

15. REMOVE POWER STEERING GEAR ASSEMBLY
a. Remove the 2 gear assembly set bolts, nuts and washers.
b. Slide the gear assembly to the right side, pullout the left side of the gear assembly from the member.

DISASSEMBLY

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

1. FIX POWER STEERING GEAR ASSEMBLY
a. Using SST, fix the gear assembly in a vise, as shown in the illustration.
SST 09630-00014 (09631-00142)

2. REMOVE TURN PRESSURE TUBE ASSEMBLY
a. Using SST, remove the 2 tubes.
SST 09023-38201

3. REMOVE CLIP, RACK BOOT AND CLAMP
a. Using pliers, loosen the clamp, as shown in the illustration.

NOTICE: Be careful not to damage the boot.

b. Remove the clip, rack boot and clamp.
c. Use the same procedure described above for the other side.

HINT: Mark the RH and LH rack boots.

4. REMOVE STEERING RACK END
a. Using a screwdriver and hammer, shake back the washer.

NOTICE: Avoid any 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.

c. Remove the claw washer.
d. Use the same procedure described above for the other side.

HINT: Mark the RH and LH rack boots.

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

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

6. REMOVE RACK GUIDE SPRING CAP
7. REMOVE RACK GUIDE SPRING AND RACK GUIDE SUB-ASSEMBLY
8. REMOVE DUST COVER

9. REMOVE CONTROL VALVE HOUSING 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.

10. 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 to damage the oil seal lip.

e. Remove the O-ring from the nut.

11. 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.

12. 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.

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)
If runout exceeds the maximum, replace the power steering rack.
b. Check the back surface for wear and damage.

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

3. 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.

REPLACEMENT

1. 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 in the correct direction.

d. Coat a new bearing with power steering fluid.
e. Using SST, press in the bearing.
SST 09950-60010 (09951-00330), 09950-70010 (09951-07150)

2. REPLACE POWER STEERING GEAR HOUSING NEEDLE ROLLER BEARING
a. Using SST, press out the oil seal from the bearing guide nut.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07100)

b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00280, 09951-00360, 09952-06010), 09950-70010 (09951-07100)

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

3. INSPECT BUSH
a. Check the inside of the bush of the cylinder end stopper for cracks. If the bush is faulty, replace the bush.
b. Apply molybdenum disulfide lithium base grease to the inside of the bush.

4. REPLACE BUSH
a. Using a screwdriver, remove the bush from the cylinder end stopper.

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

b. Coat the inside a new bush with molybdenum disulfide lithium base grease.
c. Install the bush.

5. 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.

6. REPLACE 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 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.

7. REPLACE VALVE BODY HOUSING UNION SEAT
a. Using a screw extractor, remove the union seat from the control valve housing.

b. Using a plastic-faced hammer and sliding handle, lightly tap in a new union 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 PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE

2. INSTALL POWER STEERING GEAR HOUSING SUB ASSEMBLY
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

3. INSTALL POWER STEERING GEAR HOUSING 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

4. 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 O-ring.

d. Using SST, torque the stopper.
SST 09922-10010
Torque: 110 Nm (1,122 kgf-cm, 81 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 (14.97 inch).

5. AIRTIGHTNESS TEST
a. Install SST to the unions of the rack housing.
SST 09631-12071
b. Apply 53 kPa (400 mmHg, 15.75 inHg) 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.

6. 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: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)

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

f. Using a punch, stake the nut.
7. 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 (180 kgf-cm, 13 ft. lbs.)
8. INSTALL POWER STEERING GEAR HOUSING OIL SEAL
9. 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.

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 cap 19°.

d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00011
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 09616-00011
Standard preload (turning):
Center area: 1.8 to 2.2 (18.4 to 22.4 kgf-cm, 16.0 to 19.5 inch lbs.)
End area: 1.3 to 1.7 (13.3 to 17.3 kgf-cm, 11.5 to 15.0 inch lbs.)

11. INSTALL RACK GUIDE SPRING CAP LOCK NUT
a. Apply sealant to 2 or 3 threads of the nut.
Sealant: Part No. 08833-00080, 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: 52 Nm (520 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 (14.97 inch).

c. Recheck the total preload. Standard preload (turning):
Center area: 1.8 to 2.2 (18.4 to 22.4 kgf-cm, 16.0 to 19.5 inch lbs.)
End area: 1.3 to 1.7 (13.3 to 17.3 kgf-cm, 11.5 to 15.0 inch lbs.)
d. Remove the RH and LH rack ends.

12. INSTALL CLAW WASHER AND RACK END
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: 99 Nm (1,014 kgf-cm, 74 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 (13.58 inch).

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

NOTICE: Avoid any impact to the rack.

d. Use the same procedure described above for the other side.

13. INSTALL RACK BOOT, CLAMP AND CLIP
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.
d. Use the same procedure described above for the other side.

14. INSTALL TURN PRESSURE TUBE ASSEMBLY
a. Using SST, install the 2 tubes.
SST 09023-38201
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 valve is effective in case that SST is parallel to a torque wrench.

INSTALLATION

1. INSTALL POWER STEERING GEAR ASSEMBLY
a. Slide the gear assembly to the right side, slide the gear assembly to the left side and position it.
b. Install the gear assembly with 2 new set bolts, washers and nuts.
Torque: 120 Nm (1,250 kgf-cm, 89 ft. lbs.)
2. 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 nut.
Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.)
3. CONNECT TUBE CLAMP
a. Torque the bolt.
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)

4. CONNECT RETURN TUBE ASSEMBLY
a. Using SST, connect the tube.
SST 09023-38401
Torque: 50 Nm (510 kgf-cm, 37 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.

5. CONNECT PRESSURE FEED TUBE
a. Torque the unit bolt with a new gasket.

HINT: Make sure the stopper of the pressure feed tube touches the power steering gear assembly as shown in the illustration, then torque the bolt.

Torque: 42 Nm (430 kgf-cm, 31 ft. lbs.)
6. CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY
7. INSTALL ENGINE OIL FILTER ASSEMBLY
8. CONNECT TIE ROD END SUB-ASSEMBLY LH
9. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

10. INSTALL NO. 2 ENGINE UNDER COVER
a. Tighten the 8 bolts.
11. INSTALL NO. 1 ENGINE UNDER COVER
a. Tighten the 7 bolts.
12. FACE FRONT WHEELS STRAIGHT AHEAD

HINT: Perform it with the front of the vehicle jacked up.

13. CENTER SPIRAL CABLE
14. INSTALL STEERING WHEEL ASSEMBLY
a. Align the matchmarks on the wheel and steering column main shaft.
b. Temporarily tighten the wheel set nut.
c. Connect the connector.
15. BLEED AIR FROM POWER STEERING SYSTEM
16. CHECK STEERING WHEEL CENTER POINT
17. TORQUE STEERING WHEEL SET NUT
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
18. INSTALL STEERING WHEEL PAD
19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
20. PERFORM INITIALIZATION
a. Perform initialization. Programming and Relearning
21. CHECK FRONT WHEEL ALIGNMENT
a. Check front wheel alignment.