Disassembly and Assembly
Part 1 Of 2:
Part 2 Of 2:
DISASSEMBLY
CAUTION:
^ Plug all pipe fittings, and thoroughly clean the steering gear and linkage.
^ Do disassembly and assembly in a clean area to prevent dirt or other foreign particles from entering the mechanisms.
- Disassemble in the order indicated in the table.
Tie-rod End Disassembly Note
- Mark the tie-rod end before loosening, for reference during installation.
Tie-rod End Boot Disassembly Note
1. Secure the tie rod end in a vise.
2. Place a chisel against the boot and hold it at the angle shown.
3. Remove the boot by tapping with a hammer.
Tie Rod Disassembly Note
1. Unbent the washer.
2. Remove the tie rod by using the Special Service Tool (SST).
Locknut and Adjusting Cover Disassembly Note
1. Remove the locknut by using the SST.
2. Remove the adjusting cover by using the SST.
Pinion Shaft Component Disassembly Note
- Tap the head of the pinion shaft with a plastic hammer.
Ball Bearing Disassembly Note
- Press out the ball bearing and the oil seal by using the SST.
Upper Bearing and Oil Seal Disassembly Note
- Press out the upper bearing and the oil seal by using the SST.
Clip and Rack Stop Disassembly Note
1. Turn the rack stop counterclockwise with snap-ring pliers until the end of the clip comes out.
2. Turn the rack stop in the opposite direction to remove the clip, and remove the rack stop
Rack,-Oil Seal and Backup Washer Disassembly Note
1. Install the SST over the rack end.
2. Pull out the rack with the rack bushing, oil seal, and the backup washer from the housing side.
Seal Ring and O-ring Disassembly Note
1. Remove the seal rings by using a small, tape-wrapped screwdriver.
2. Remove the O-ring.
RACK INSPECTION
1. Inspect for cracking, damage, and tooth wear. Replace as necessary.
2. Measure the runout of the rack.
Runout: 0.4 mm (0.016 inch) max.
3. If not within the specification, replace the rack.
TIE ROD INSPECTION
1. Inspect the tie rod for bending and damage. Replace it as necessary.
2. Inspect the ball joint for looseness. Replace the tie rod as necessary.
3. Swing the tie rod five times.
4. Measure the swinging torque by using a pull scale.
Swinging torque: 0.1 - 3.4 Nm (0.9 - 30 inch lbs.).
Pull scale reading: 0.6 - 24.5 N (0.16 - 5.5 lbs.).
5. If not within the specification, replace the tie rod.
TIE-ROD END INSPECTION
1. Inspect the ball joint for looseness. Replace the tie-rod end as necessary.
2. Rotate the ball joint five times.
3. Measure the rotation torque of the ball joint by using the SST and a pull scale.
Rotation torque: 0.3 - 3.9 Nm (2.6 - 34 inch lbs.).
Pull scale reading: 3 - 29 N (0.7 - 6.6 lbs.).
4. If not within the specification, replace the tie-rod end.
ASSEMBLY
Part 1 Of 2:
Part 2 Of 2:
- Assemble in the order indicated in the table.
Backup Washer and On Seal (Gear Housing) Assembly Note
1. Apply ATF to the new oil seal.
2. Install the backup washer and oil seal by using the Special Service Tools (SSTs).
3. After installing, shake the gear housing and verify that the backup washer does not rattle.
4. If it rattles, remove the oil seal and backup washer, and install them.
Steering Rack Assembly Note
1. Apply ATF to a new O-ring and seal ring.
2. Install the O-ring and seal ring in the piston groove.
3. Apply grease to the friction surface and teeth of the rack.
4. Slide the vinyl sleeve (supplied in the seal kit) over the rack, and slide the rack in from the tube side.
5. Remove the vinyl sleeve.
Oil Seal and O-ring Assembly Note
1. Apply ATF to a new oil seal.
2. Set a plate on the oil seal and press it into the rack bushing until the plate contacts the edge of the rack bushing.
3. Apply ATF to the new O-ring.
4. Install the O-ring onto the groove of the rack bushing.
Rack Bushing Assembly Note
1. Apply ATF to the friction surface of the rack bushing.
2. Slide the SST over the end of the rack and install the rack bushing.
Rack Stop and Clip Assembly Note
1. Using snap-ring pliers, turn the rack stop into the rack housing until the holes of the rack housing and the rack bushing are aligned.
2. Insert the clip through the holes and turn the rack stop to install it.
3. Perform the hermetic inspection as follows.
(1) Connect the SST (adapters) to the cylinder housing.
(2) Connect the vacuum pump to the SST (hose) and apply 400 mm Hg (15.7 inches Hg) vacuum.
(3) Verify that vacuum pressure is maintained for at least 30 seconds. If not, replace the oil seal.
Seal Ring Assembly Note
1. Apply ATF to new seal rings.
2. Install the seal rings onto the pinion shaft component.
3. Pass the pinion shaft component back and forth through the SST until the seal rings are set.
4. Install the oil seal on the gear side of the pinion shaft.
Oil Seal and Upper Bearing Assembly Note
1. Apply grease to the lip of a new oil seal.
2. Press the oil seal into the valve housing by using the SST.
3. Press the upper bearing in the valve housing by using the SST.
Ball Bearing Assembly Note
- Press the ball bearing into the pinion shaft by using the SST.
Adjusting Cover and Locknut Assembly Note
1. Apply sealant to the threads of the adjusting cover.
2. Tighten the adjusting cover to 20 - 29 Nm (14 - 22 ft. lbs.) by using the SST, and return it 25° - 30°.
3. While keeping the adjusting cover from turning, tighten the locknut by using the SST.
Tightening torque: 50 - 68 Nm (37 - 50 ft. lbs.).
4. Measure the pinion preload as follows.
(1) Attach the SST and a pull scale to the pinion shaft.
(2) Measure the pinion preload. (Center of racks 90°)
Pinion preload: 0.5 - 1.3 Nm (4 - 12 inch) max.
Pull scale reading: 5.0 - 13.7 N (1.1 - 3.0 lbs.).
(3) If not within the specification, adjust the adjusting cover.
Tie Rod Assembly Note
1. Install the tie rod by using the SST .
Tightening torque: 79 - 98 Nm (58 - 72 ft. lbs.).
2. Bend the new washer at the two points by using a punch.
Boot and Boot Clamps Assembly Note
1. Apply grease to the inner surface of the small end of the boot.
2. Install the boot and the new boot clamp as shown in the figure.
3. Install the new small boot clamp.
4. Slide the rack fully in and out to verify that the boot is not twisted.
Tie-rod End Boot Assembly Note
1. Wipe away the grease on the ball joint.
2. Put a small amount of grease (lithium-based) into the new boot and set it onto the tie-rod end.
3. Press the boot onto the tie-rod end by using the SST and a press.
4. Wipe away any grease expelled from the dust boot.
Tie-rod End
- Install the tie-rod end so that it is aligned with the reference marks.