Disassembly and Assembly
Part 1 Of 2:
Part 2 Of 2:
DISASSEMLBY
Disassemble in the order indicated in the illustration, noting the following.
Oil Pipe Disassembly Note (1)
1. Secure the gear in a vise.
2. Remove the oil pipe.
Tie-rod End Disassembly Note (2)
Mark the tie-rod end before loosening, for reference during installation.
Tie-rod End Boot Disassembly Note (3)
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 (8)
1. Unbend the washer.
2. Remove the tie rod by using the Special Service Tool (SST).
Locknut Disassembly Note (11)
Remove the locknut by using the SST.
Housing Cover Disassembly Note (15)
1. Drill away the staked areas.
2. Remove the housing cover.
Outer Box Disassembly Note (24)
Remove the outer box by using the SST.
Oil Seal And Inner Guide Disassembly Note (30 & 31)
Remove the oil seal and inner guide by using the SSTs.
Oil Seal (Pinion) Disassembly Note (32)
Remove the oil seal by using the SST.
TIE-ROD END INSPECTION
1. Inspect the tie-rod end for damage and boot cracks. Replace it if necessary.
2. Inspect the ball joint for looseness. Replace the tie rod end as necessary.
3. Rotate the ball joint five times.
4. Measure the rotation torque of the ball joint by using the Special Service Tool (SST) and a pull scale.
Rotation torque: 0.3 - 2.9 Nm (2.6 - 26 inch lbs.)
Pull scale reading: 3 - 29 N (0.7 - 6.6 lbs.)
5. If not within the specification, replace the tie-rod end.
TIE ROD INSPECTION
1. Inspect the tie rod for bending and damage. Replace it if 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: 0.7 - 21 N (0.16 - 4.8 lbs.)
5. If not within the specification, replace the tie rod.
STEERING RACK INSPECTION
1. Inspect for cracking, damage, and tooth wear. Replace if necessary.
2. Measure the runout of the rack.
Runout:
A: 0.3 mm (0.012 inch) max.
B: 0.4 mm (0.016 inch) max.
3. If not within the specification, replace the rack.
Part 1 Of 2:
Part 2 Of 2:
ASSEMBLY
Assemble in the order indicated in the illustration, noting the following steps.
Oil Seal (Pinion) Assembly Note (5)
1. Apply grease to the new oil seal.
2. Install the oil seal in the gear housing by using the
Steering Rack Assembly Note (6)
1. Apply ATF to a new O-ring and seal ring.
2. Install the O-ring and seal ring in the groove.
3. Hold the seal ring and O-ring.
4. Apply ATF to the inner guide and oil seal.
5. Install the inner guide and oil seal to the Special Service Tool (SST) (49 B032 31 9) by using the SST (49 B032 318), or equivalents.
6. Place the oil seal and inner guide at the edge of the steering rack's pinion by using the SST.
7. Remove the SST.
8. Install the steering rack in to gear box.
9. Press the oil seal and inner guide to the correct position.
Outer Box Assembly Note (13)
1. Install the SST (49 B032 313), or equivalent to the steering rack.
2. Install the outer box, and use the SST (49 T032 312), or equivalent to tighten.
3. Remove the SST (49 B032 313), or equivalent.
Hermetic Sealing Inspection Of Cylinder
1. Connect the SSTs (49 G032 336 and 49 G032 119), or equivalents to the cylinder housing.
2. Connect a vacuum pump to the SST (49 G032 317), or equivalent and apply 53.3 kPa (15.7 inches Hg) vacuum.
3. Verify that vacuum is held for at least 30 seconds. If not, replace the oil seal.
Seal Ring Assembly Note (13)
1. Install the new seal ring to the pinion shaft by using the SST (49 E032 305), or equivalent.
2. Slide the SST (49 E032 306), or equivalent over the seal ring until they are set in the grooves.
Pinion Shaft Assembly Note (15)
Install the pinion shaft to the gear housing by using the SST
Bearing Assembly Note (16)
1. Apply grease to the bearing.
2. Install the bearing to the gear housing by using the SST.
Oil Seal Assembly Note (17)
1. Apply grease to the new oil seal.
2. Install the oil seal to the gear housing by using the SST.
Adjusting Cover and Locknut Assembly Note (25 & 26)
1. Apply sealant to the threads of the adjusting cover.
2. Tighten the adjusting cover to 4.9 Nm (43 inch lbs.) by using the SSTs and return it about 25 degrees.
Inspection Of Pinion Preload
1. Attach the SST and a pull scale to the pinion shaft.
2. Measure the pinion preload.
Rack position: Center ± 90°
Pinion preload: 1.0 - 1.2 Nm (8.7 - 10.4 inch lbs.) max.
Pull scale reading: 9.9 - 12 N (2.2 - 2.6 lbs.)
3. If not to the specification, readjust by turning the adjusting cover 0 - 25 degrees.
4. Apply the sealant to the threads of the locknut.
5. Tighten the locknut while holding the adjusting cover by using the SST.
Tie-rod End Boot Assembly Note (33)
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 Assembly Note (34)
Install the tie-rod end, aligning the marks made before disassembly.