Overhaul
POWER STEERING GEAR BOXINSPECTION 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 be fixed to the jaws. If other section is fixed the 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. Standard value
Total pinion preload: 0.6 - 1.3 N-m (0.06..13 kgf-m..4 - 1.0 lb-ft)
NOTE: Measure the pinion preload through the entire stroke of the rack.
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).
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..044 Nm (0.44kg-cm..03 lb-ft) 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. Remove the bellows band (A).
3. Remove the bellows clip (A).
4. Pull the bellows out toward the tie rod.
NOTE: Check for rust on the rack when the bellows are replaced.
5. Remove the feed tube (A) from the rack housing.
6. While moving the rack slowly, drain the fluid from the rack housing.
7. Remove the tie rod (B) from the rack (A).
CAUTION: Remove the tie rod (B) from the rack (A), taking care not to twist the rack.
8. Remove the yoke plug locking nut (A).
9. Remove the yoke plug (A) with a 14 mm socket.
10. Remove the lock nut (D), yoke plug (C), rack support spring (B) and rack support yoke (A) from the gear box.
11. When the end of the circlip comes out of the notched hole (B) of the housing rack cylinder (C), turn the rack stopper (A) clockwise and remove the circlip.
CAUTION: Be careful not to damage the rack.
12. Remove the rack bushing and rack from the rack housing.
13. Remove the O-ring (A) from the rack bushing (B).
14. Remove the oil seal (B) from the rack bushing (A).
15. Remove the valve body from the valve body housing with a soft hammer.
16. Using the special tool, remove the oil seal and ball bearing from the valve body housing.
17. 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.
18. Using the special tool (09573-21200.9555-21000), 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
1) Check for rack tooth face damage or wear
2) Check for oil seal contact surface damage
3) Check for rack bending or twisting
4) Check for oil seal ring damage or wear
5) Check for oil seal damage or wear
VENT HOLE
2. Pinion valve
1) Check for pinion gear tooth face damage or wear
2) Check for oil seal contact surface damage
3) Check for seal ring damage or wear
4) Check for oil seal damage or wear
3. Bearing
1) Check for seizure or abnormal noise during a bearing rotation
2) Check for excessive play
3) Check for missing needle bearing rollers
4. Others
1) Check for damage of the rack housing cylinder bore
2) 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-III
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-III
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).
8. Using a special tool, install the oil seal and the ball bearing in the valve body housing.
9. After applying the specified fluid and grease to the pinion valve assembly (A), install it in the rack housing assembly.
10. Install the rack support yoke (A), rack support spring (B), yoke plug (C) and lock nut (D) in the order shown in the illustration. Apply semi-drying sealant to the threaded section of the yoke plug before installation.
11. Install the locking nut with a specified torque, after adjusting the rack support yolk as following instruction.
1) Place the rack in the center position.
2) Tighten the York plug with a specified torque.
Specified torque Nm(kgf-m,lb-ft):
Manual 9 - 11(0.9 - 1.1,6.5 - 7.9), Power 20(2,14.5)
3) Reciprocate the rack slowly 5 times.
4) Place the rack in the center position again, and then loosen the York plug.
5) Tighten the York with a specified torque, and turn at a certain degree in reverse.
Specified torque Nm(kgf-m,lb-ft):
Manual 4.5 - 6.5(0.45 0.65, 3.25 - 4.70), Power 5 - 6(0.5..6,3.62 - 4.34)
Reverse angle: 25 ± 5 (Manual), 35 (Power)
6) Tighten the yoke lock nut without moving yoke plug.
12. Tighten the feed tube (A) to the specified torque and install the mounting rubber using adhesive.
13. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
14. Install the new attaching band to the bellows.
NOTE: When the bellows are installed, a new band must be used.
15. Install the bellows in position, taking care not to twist it.
16. Install temporarily the tie rod (A) to the tie rod end (B).
17. Check for total pinion preload.
