Overhaul
POWER STEERING GEAR BOXDISASSEMBLY
1. Remove the tie rod end (13) from the tie rod (A).
2. Remove the dust cover (13) from the ball joint (A).
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 (A) 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 (A).
CAUTION: Remove the tie rod(B) from 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 14mm socket (A).
12. Remove the lock nut (D), yoke plug (C), rack support spring (B) and rack support yoke (A) from the gear box.
13. When the end of the circlip comes out of the notched hole (B) of the housing rack cylinder, turn the rack stopper(A) clockwise and remove the circlip.
CAUTION: Be careful not to damage the rack.
14. When the end of the circlip comes out of the notched hole (A) of the housing rack cylinder, turn the rack stopper (B) counterclockwise and remove the circlip.
CAUTION: Be careful not to damage the rack.
15. Remove the rack bushing and rack from the rack housing.
16. Remove the O-ring (A) from the rack bushing (B).
17. Remove the oil seal (B) from the rack bushing (A).
18. Remove the valve body (A) from the valve body housing (B) with a soft hammer.
19. Using the special tool, remove the oil sea[ 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(09573-33100, 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
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.
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-4
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-4
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.
Recommended grease Multi-purpose grease SAE J310a NLGI No.2
NOTE: Do not plug the vent hole(A) in the rack with grease.
7. Insert the rack (A) into the rack housing (B) and install the rack bushing (C).
8. Push in the rack stopper (A) until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing. Then, install the circlip while turning the rack stopper.
CAUTION: The circlip should not be visible through the notched hole of the rack housing.
9. Using special Tool(09432-21600), 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 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.
13. With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to 12 Nm (120 kg-cm, 8.9 lb-ft), with a 14mm socket (A). Loosen the yoke plug approximately from 30° to 60° and tighten the yoke nut to the specified torque.
14. Tighten the feed tube (A) to the specified torque and install the mounting rubber using adhesive.
15. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
16. Install the new attaching band to the bellows.
NOTE: When the bellows are installed, a new band must be used.
17. Install the bellows in position, taking care not to twist it.
18. 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.
Recommended grease
A: POLY LUB GLY 801 K or equivalent
B: SHOW AA SUNLIGHT M132 or equivalent
Dust cover inner side and lip: THREE BOND
19. Install the tie rod end (B) to the tie rod (A).
