Disassembly and Assembly

INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY





Fix a brass plate or aluminum plate for protection to the jaws of a vise and mount the gear box(A) in a vise(B).

CAUTION: When mounting the gear box in a vise, let the installation section of it tee fixed to the laws. If other section is fixed me gear box may be damaged.

TOTAL PINION PRELOAD





1. Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload.
2. If the measured value is out of specifications, first adjust the yoke plug(A), then recheck the total pinion preload.
3. If you adjust the yoke plug but do not obtain the total pinion preload, check or replace the yoke plug components

TIE ROD SWING RESISTANCE
1. Rotate the tie rod severely ten times.





2. Measure the tie rod(A) swing resistance with a spring scale(B).
Standard value
Total rod swing resistance: 8 - 22 N (1.9 - 4.6 lbs.) [2 - 5 Nm (20 - 50 kgf-cm, 17 - 43 inch lbs.)]
3. If the measured value exceeds the standard value, replace the tie rod assembly.

CAUTION: Even if the measured value is below the standard value, the tie rod that swings smoothly without excessive play may be used. If the measured value is below 4.3 N (0.9 lb) 100 Ncm (8.7 inch lbs.)], replace the tie rod.

BELLOWS INSPECTION
1. Inspect the bellows for damage or deterioration.
2. Make sure the bellows are secured in the correct position.
3. If the bellows are defective, replace them with new ones.

DISASSEMBLY





1. Remove the tie rod, end(B) from the tie rod(A).





2. After mounting the tie rod end(A) in a vise, remove the dust cover(B) from the ball joint.





3. Remove the bellows band(A).





4. Remove the bellows clip(A).
5. Pull the bellows out toward the tie rod.

NOTE: Check for rust on the rack when the bellows are replaced.

6. Remove the feed tube from the rack housing.
7. While moving the rack slowly, drain the fluid from the rack housing.





8. Unstake the tab washer(A) which fixes the tie rod(B) and rack(C) with a chisel.





9. Remove the tie rod(B) from the rack(C).

CAUTION: Remove the tie rod(B) tram the rack(A), taking care not to twist the rack.





10. Remove the yoke plug locking nut(A).





11. Remove the yoke plug(B) with a 14 mm socket(A).





12. Remove the lock nut(A), yoke plug(B), rack support spring(C), rack support yoke(D) and bushing(E) from the gear box.





13. Remove the valve body housing(A) by loosening the two bolts(B).





14. Turn the rack stopper(A) clockwise until the end of the circlip(B) comes out of the slot in the rack housing(C).





15. When the end of the circlip(A) comes out of the notched hole of the housing rack cylinder, turn the rack stopper(B) counterclockwise and remove the circlip(A).





16. Remove the O-ring(A) from the rack bushing(B).





17. Remove the oil seal(A) from the rack bushing(B).





18. Remove the valve body(A) from the valve body housing(B) with a soft hammer(C).
19. Using the special tool, remove the oil seal and ball bearing from the valve body housing.
20. Remove the oil seal and O-ring from the rack housing.

CAUTION: Be careful not to damage the pinion valve cylinder inside of the rack housing.





21. Using the special tool (06573-21200, 09555-21000), remove the oil seal(A) from the rack housing.

CAUTION: Be careful not to damage the rack cylinder inside of the rack housing.

INSPECTION





1. Rack
- Check for rack tooth face damage or wear
- Check for oil seal contact surface damage
- Check for rack bending or twisting
- Check for oil seal ring damage or wear
- Check for oil seal damage or wear





2. Pinion valve
- Check for pinion gear tooth face damage or wear
- Check for oil seal contact surface damage
- Check for seal ring damage or wear
- Check for oil seal damage or wear
3. Bearing
- Check for seizure or abnormal noise during rotating a bearing
- Check for excessive play
- Check for missing needle bearing rollers
4. Others
- Check for damage of the rack housing cylinder bore
- Check for boot damage, cracking or aging

REASSEMBLY
1. Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid: PSF-3





2. Install the backup washer and oil seal(A) to the specified position in the rack housing.
3. Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid: PSF-3





4. Install the oil seal(A) in the rack bushing(B).
5. Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.





6. Apply the specified grease to the rack teeth.





7. Insert the rack(A) into the rack housing(B) and install the rack bushing(C) and rack stopper(D).





8. Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing. Install the circlip(A) while turning the rack stopper.

CAUTION: The circlip end should not be visible through the notched how of the rack housing.





9. Install the oil seal and the ball bearing in the valve body(A).





10. After applying the specified fluid and grease to the pinion valve assembly(A), install it in the rack housing assembly.





11. After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly(A) and O-ring in the gear box(B).





12. Install the tab washer and the tie rod and stake the tab washer(A) end at two points over the tie rod.





13. Install the bushing(A), rack support yoke(B), rack support spring(C), lock nut(E) and yoke plug(D) in the order shown in the illustration. Apply semi-drying sealant to the threaded section of the yoke plug before installation.





14. With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to 15 Nm (150 kgf-cm, 11 ft. lbs.), using the special tool. Loosen the yoke plug approximately from 30° to 60° and tighten the locking nut to the specified torque.
15. Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.





16. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Recommended grease: Silicone grease
17. Install the new attaching band to the bellows.

NOTE: When the bellows are installed, a new band must be used.

18. Install the bellows in position, taking care not to twist it.





19. Fill the dust cover inner side and lip with the specified grease, and fix the dust cover in position with the clip ring attached in the groove of the tie rod end.





20. Install the tie rods so that the length of the left and right tie rods equals the standard value.
21. Check for total pinion preload.