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Home >> Mazda >> 1999 >> Protege ES L4-1839cc 1.8L DOHC >> Repair and Diagnosis >> Steering and Suspension >> Steering >> Steering Gear >> Service and Repair >> Disassembly and Assembly

Disassembly and Assembly

STEERING GEAR AND LINKAGE DISASSEMBLY








1. Disassemble in the order indicated in the table.

Tie Rod Disassembly Note
1. Unclamp the washer.





2. Remove the tie rod.

Locknut (Adjusting Cover) Disassembly Note





1. Remove the locknut using the SST.

Pinion Shaft And Housing Component Disassembly Note





1. Remove the socket bolts (2 points) which fix the pinion shaft and housing.





2. Hold the pinion shaft as shown, and pull the pinion shaft out and housing component.

Pinion Shaft Component Disassembly Note

NOTE: If the pinion shaft does not come out easily, remove it using a press.





1. Push the pinion shaft component out from the valve housing as shown.

Snap Ring Disassembly Note





1. Carefully remove the snap ring without damaging the pinion shaft component.

Upper Bearing Disassembly Note
1. Set the SST as shown.





2. Using a press, remove the oil seal and upper bearing without applying pressure to the edge of the valve housing.

Holder Disassembly Note





1. Cut away the staked area using a drill.

CAUTION: Carefully pull the holder out without damaging the U-gasket.





2. Disassemble the holder using the SST.

Inner Guide Disassembly Note
1. Set the SSTs into the valve side.
2. Install the SST to the gear housing.





3. Press the oil seal and inner guide out.

Mounting Rubber Disassembly Note





1. Press the mounting rubber out from the gear housing using the SSTs and a Dress.

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 it with a hammer.

STEERING GEAR AND LINKAGE INSPECTION
Rack Inspection
1. Inspect the rack for cracking, damage, and tooth wear.
- Replace it as necessary.





2. Measure the runout of the rack.
- If not within the specification, replace the rack.

Runout
Near point A: 0.15 mm (0.006 inch) max.
Near point B: 0.20 mm (0.008 inch) max.

Tie-Rod End Inspection
1. Inspect the tie-rod end for damage and boot cracks.
- Replace it as 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 bail joint using the SST and a pull scale.
- If not within the specification, replace the tie-rod end

Rotation torque 0.4 - 2.7 Nm (3.5 - 26.0 kgf.cm, 3.1 - 22.5 inch lbs.)
Pull scale reading 3.4 - 25.5 Nm (0.35 - 2.60 kgf, 0.8 - 5.7 lbs.)

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 using a pull scale.
- If not within the specification, replace the tie rod.

Swinging torque 0.1 - 4.0 Nm (1 - 39 kgf-cm, 0.9 - 33.8 inch lbs.)
Pull scale reading 0.6 - 24.5 Nm (0.06 - 2.50 kgf, 0.2 - 5.5 lbs.)

STEERING GEAR AND LINKAGE ASSEMBLY








1. Assemble in the order indicated in the table.

Tie-Rod End Boot Assembly Note
1. Wipe the grease off the ball joint.
2. Put a small amount of lithium-based grease into a new dust boot.
3. Install the dust boot onto the tie-rod end using the SST and a press.





4. Wipe away any excessive grease.

Mounting Rubber Assembly Note
1. Apply soapy water to the rubber part of the mounting rubber.





2. Press the mounting rubber until the mounting rubber end comes out completely from the gear housing using the SSTs and a press.

NOTE: Mounting rubber end and steel plate shall be aligned.





3. Reverse the gear housing, then press the mounting rubber until the mounting rubber end comes completely out the other side.

Oil Seal Assembly Note
1. Install a new O-ring and new seal ring to the rack's piston.
2. After installing the seal ring, seat it properly at the piston circumference.





3. Install a new oil seal to the SST (49 B032 319) using the SST (49 B032 318).
4. Remove the SST (49 B032 318).





5. Using the SST, place the oil seal at the edge of the steering rack's Piston and remove the SST.
6. Install a new inner guide to the steering rack.

CAUTION: When pressing in, do not apply a load pressure of more than 39 kPa (400 kgf/cm2, 5688 psi). Doing so will damage the oil seal and inner guide.





7. After installing the steering rack to the gear housing, press the oil seal and inner guide using the SST until the force required suddenly Increases.

Holder Assembly Note
1. Apply grease to the U-gasket and O-ring.
2. Assemble the U-gasket and O-ring into the holder.





3. Assemble the SST to the steering rack.





4. Assemble the holder using the SST.





5. Stake the holder to the cylinder using a punch.

Oil Seal Assembly Note
1. Apply grease to a new oil seal.





2. Press in the new oil seal using the SSTs

Upper Bearing Assembly Note
1. Apply grease to a new upper bearing.





2. Press in the new oil seal using the SSTs.

Seal Ring Assembly Note
1. Install a new seal ring to the valve part of the pinion shaft using the SST.





2. After installing it. seat it properly using the SST.
3. Install the snap ring.

Adjusting Cover Assembly Note
1. Set the rack to the center position.





2. Tighten the adjusting cover to 19.6 Nm (2.0 kgf-m, 14.5 ft. lbs.) three times, then return it 23° using the SST.
3. Apply sealant to the threads of the locknut.
4. Attach the locknut.





5. Measure the pinion torque using the SST and a pull scale.
- If not as specified, reseat Steps 2 through 5.





6. Install the locknut using the SST.

HERMETIC SEALING INSPECTION





1. Connect the SSTs to the power cylinder section of the gear housing.
2. Apply 53.3 kPa (400 mmHg, 15.7 inHg) vacuum with a vacuum pump and verify that it is held for at least 30 seconds.
- If the vacuum is not held, replace the oil seal.

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