Disassembly and Assembly
DISASSEMBLY
NOTICE: When using a vise, do not overtighten it.
1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the PS gear assembly in a vise.
SST 09612-00012
2. REMOVE 2 TURN PRESSURE TUBES
a. Using SST, remove the 2 turn pressure tubes.
SST 09633-00020
b. Remove the 4 O-rings from the 2 turn pressure tubes.
3. REMOVE RH AND LH TIE ROD ENDS AND LOCK NUTS
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.
c. Employ the same manner described above to the other side.
4. REMOVE RH AND LH CLIPS, RACK BOOTS AND CLAMPS
a. Using pliers, loosen the clamp.
NOTICE: Be careful not to damage the boot.
b. Remove the clip and boot.
HINT: Mark the RH and LH rack boots.
c. Employ the same manner described above to the other side.
5. REMOVE RH AND LH RACK ENDS AND CLAW WASHERS
a. Using a chisel and hammer, unstake the washer.
NOTICE: Avoid any impact on the steering rack.
b. Using SST, remove the rack end and claw washer. SST 09922-10010
NOTICE: Use SST 09922-10010 in the direction shown in the illustration.
HINT: Mark the RH and LH rack ends.
c. Employ the same manner described above to the other side.
6. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the rack guide spring cap lock nut. SST 09922-10010
NOTICE: Use SST 09922-10010 in the direction shown in the illustration.
7. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING, CONICAL SPRING WASHER, RACK GUIDE SUB-ASSEMBLY
a. Using a hexagon wrench (19 mm), remove the rack guide spring cap.
b. Remove the rack guide spring, conical spring washer, rack guide sub-assembly.
8. REMOVE RACK HOUSING CAP
9. REMOVE SELF-LOCKING NUT
Using SST, stop the control valve shaft rotating and remove the self-locking nut.
SST 09616-00010
10. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place matchmarks on the control valve housing and rack housing.
b. Remove the 2 bolts and control valve housing with the control valve assembly.
c. Remove the gasket from the control valve housing.
11. REMOVE CONTROL VALVE ASSEMBLY AND OIL SEAL
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
b. Using a plastic hammer, tap out the control valve assembly with the oil seal from the control valve housing.
NOTICE: Be careful not to damage the oil seal lip.
c. Remove the oil seal from the control valve assembly.
12. REMOVE CYLINDER END STOPPER
a. Using SST, turn the cylinder end stopper clockwise until the wire end is visible through the service hole.
SST 09631-10021
b. Using SST, turn the cylinder end stopper counterclock wise, and remove the wire.
SST 09631-10021
13. REMOVE STEERING RACK WITH BUSHING
a. Using SST, press out the steering rack with the bushing.
SST 09612-24014 (09612-10061)
NOTICE: Take care not to drop the steering rack.
b. Remove the O-ring from the bushing.
14. REMOVE OIL SEAL
Using SST, press out the oil seal.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07360)
NOTICE: Do not damage the rack housing.
INSPECTION
NOTICE: When using a vise, do not overtighten it.
1. INSPECT STEERING RACK
a. Using a dial indicator, check the steering rack for runout and for teeth wear and damage.
Maximum runout: 0.30 mm (0.0118 inch)
b. Check the back surface for wear and damage.
REPLACEMENT
NOTICE: When using a vise, do not overtighten it.
1. 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 (09951-07100)
b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07100)
NOTICE: Make sure to install the oil seal facing in the correct direction.
d. Coat a new bearing with molybdenum disulfide lithium base grease.
e. Using SST, press in the bearing.
SST 09950-60010 (09951-00190, 09951-00360, 09952-06010), 09950-70010 (09951-07100)
2. IF NECESSARY, REPLACE 2 BEARINGS
a. Using SST, press out the bearing from the steering rack housing.
SST 09950-70010 (09951-07100)
b. Using SST, press out the bearing from the steering rack housing.
SST09950-70010 (09951-07100)
c. Coat a new bearing with molybdenum disulfide lithium base grease.
d. Using SST, press in the bearing.
SST 09950-60010 (09951-00220, 09951-00280, 09952-06010), 09950-70010 (09951-07100)
e. Coat a new bearing with molybdenum disulfide lithium base grease.
f. Using SST, press in the bearing.
SST 09950-60010 (09951-00280), 09950-70010 (09951-07100)
3. IF NECESSARY, REPLACE OIL SEAL
a. Using SST, remove the oil seal from the bushing.
SST 09612-24014 (09613-22011)
NOTICE: Be careful not to damage the bushing.
HINT: As shown in the illustration, from the opposite side of SST confirm that its claws are firmly caught on the oil seal.
b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00230, 09951-00370, 09952-06010), 09950-70010 (09951-07100)
NOTICE: Make sure to install the oil seal facing in the correct direction.
4. IF NECESSARY, REPLACE TEFLON RING
a. Using a screwdriver, remove the teflon ring from the steering rack.
NOTICE: Be careful not to damage the groove for the teflon ring.
b. Expand a new teflon ring with your fingers.
NOTICE: Be careful not to overexpand the teflon ring.
c. Coat the teflon ring with power steering fluid.
d. Install the teflon ring to the steering rack and settle it down with your fingers.
e. Carefully slide the tapered end of SST over the teflon ring until it fits to the steering rack.
SST 09630-24014 (09631-24031)
NOTICE: Be careful not to damage the teflon ring.
5. IF NECESSARY, REPLACE 4 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 teflon ring.
b. Expand 4 new teflon rings with your fingers.
NOTICE: Be careful not to overexpand the teflon ring.
c. Coat the teflon rings with power steering fluid.
d. Install the teflon rings to the control valve assembly, and settle them down with your fingers.
e. Carefully slide the tapered end of SST over the teflon rings until them fit to the control valve assembly.
SST 09631-20081
NOTICE: Be careful not to damage the teflon rings.
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 OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST, press in the oil seal.
SST 09950-60010 (09951-00240, 09951-00400, 09952-06010), 09950-70010 (09951-07360)
NOTICE:
^ Make sure to install the oil seal facing in 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 steering rack.
SST 09631-16020
HINT: If necessary, scrape the burrs off the steering 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 BUSHING
a. Coat a new O-ring with power steering fluid and install it to the bushing.
b. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
c. Install the bushing into the rack housing.
NOTICE:
^ Make sure to install the bushing facing in the correct direction.
^ Be careful not to damage the oil seal lip.
5. INSTALL CYLINDER END STOPPER
a. Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing.
b. Install a new wire into the cylinder end stopper.
c. Using SST, turn the cylinder end stopper clockwise 450 ± 50°.
SST 09631-10021
6. AIR TIGHTNESS TEST
a. Install SST to 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. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
b. Coat the teflon rings with power steering fluid.
c. Install the control valve assembly into the control valve housing.
NOTICE: Be careful not to damage the teflon rings and oil seal.
8. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST, press in the oil seal.
SST 09612-22011
NOTICE: Make sure to install the oil seal facing in the correct direction.
9. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place a new gasket on the rack housing.
b. Align the matchmarks on the control valve housing and rack housing.
c. Install the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
10. INSTALL SELF-LOCKING NUT
Using SST, stop the control valve shaft rotating and Install a new self-locking nut. SST 09616-00010
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
11. INSTALL RACK HOUSING CAP
a. Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Install the rack housing cap.
Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.)
c. Using a punch and hammer, stake the 2 parts of the rack housing cap.
12. INSTALL RACK GUIDE SUB-ASSEMBLY, CONICAL SPRING WASHER, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
a. Install the rack guide sub-assembly, conical spring washer and rack guide spring.
b. Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Temporarily install the rack guide spring cap.
13. 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. Using a hexagon wrench (19 mm), install the rack guide spring cap.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
c. Using a hexagon wrench (19 mm), return the cap 12°.
d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00010
e. Using a hexagon wrench (19 mm), loosen the rack guide spring cap until the rack guide spring is not functioning.
f. Using SST, a torque wrench and hexagon wrench (19 mm), tighten the rack guide spring cap until the preload is within the specification.
SST 09616-00010
Preload (turning): 0.8 - 1.4 Nm (8 - 14 kgf-cm, 6.9 -12.2 inch lbs.)
14. INSTALL RACK GUIDE SPRING CAP LOCK NUT
a. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.
Sealant: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Temporarily install the lock nut.
c. Using a hexagon wrench (19 mm), hold the rack guide spring cap and using SST, torque the nut.
SST 09922-10010
Torque: 43 Nm (439 kgf-cm, 32 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).
d. Recheck the total preload.
Preload (turning): 0.8 - 1.4 Nm (8 - 14 kgf-cm, 6.9 -12.2 inch lbs.)
e. Remove the RH and LH rack ends.
15. INSTALL RH AND LH CLAW WASHERS AND RACK ENDS
a. Install a new claw washer, and temporarily install the rack end.
HINT: Align the claws of the washer with the steering rack grooves.
b. Using SST, torque the rack end.
SST 09922-10010
Torque: 62 Nm (633 kgf-cm, 46 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 (14.96 inch).
c. Using a brass bar and a hammer, stake the washer.
NOTICE: Avoid any impact on the steering rack.
d. Employ the same manner described above to the other side.
16. INSTALL RH AND LH RACK BOOTS, CLAMPS AND CLIPS
a. Make sure that the steering rack hole is not clogged with grease.
HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.
b. Install the boot clip and a new clamp.
NOTICE: Be careful not to damage or twist the boots.
c. Using SST, tighten the clamp as shown in the illustration.
SST 09521-24010
d. Employ the same manner described above to the other side.
17. 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: 56 Nm (570 kgf.cm, 41 ft. lbs.)
18. INSTALL 2 TURN PRESSURE TUBES
a. Coat 4 new O-rings with power steering fluid and install them to the 2 turn pressure tubes.
b. Using SST, install the 2 tubes.
SST 09633-00020
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
HINT:
^ Use a torque wrench with a fulcrum length of 250 mm (9.84 inch).
^ This torque value is effective in case that SST is parallel to a torque wrench.