Field-Fix Procedure

Remove Power Steering Gear from vehicle as described in the Repair Manual (page SR-44).

1. Mark the outer tie rod ends/tie rod lock nut and the inner tie rod prior to removing the steering rack.

2. Index the steering column U-joint to the steering rack pinion shaft (control valve shaft) prior to removing the steering rack.

3. Disconnect the power steering pressure lines from the steering rack.

Replace the Power Steering Rack Guide.





The original roller-type steering rack guide will be changed to a seat-type steering rack guide. The illustration details the rack guide parts to be installed.

1. Rack Guide Installation

a. Remove original rack guide.

b. Assemble rack guide seat and rack guide together by inserting seat clip into the center hole of the guide.

c. Apply approximately 2 grams of chassis grease to the surface of the rack guide seat which will be in contact with the steering rack.

d. Install the rack guide with the rack guide seat into the steering rack housing..

2. Install the Rack Guide Spring and Wave Washer.

a. Apply a thin coat of chassis grease to the end of the rack guide spring to prevent it from being dropped.





b. Install the wave washer in the direction indicated in the illustration.

c. Install the rack guide spring in the direction indicated in the illustration.





3. Rack Guide Spring Cap Installation.

a. Clean the screw threads on the rack guide cap and the steering rack housing.

b. Apply LOCTITE 242 or equivalent to the screw thread area on the rack guide cap.

c. Install rack guide cap using SST 09616-10022-02.

Torque: 7.2 ft-lb., (86 in.lb., 100 kgfcm, 9.8 Nm)

d. Loosen rack guide cap and retorque.

Torque: 7.2 ft-lb., (86 in.lb., 100 kgfcm, 9.8 Nm)

e. Loosen rack guide cap and retorque.

Torque: 3.6 ft-lb., (43 in.lb., 50 kgfcm, 4.9 Nm)

NOTE:
Use this procedure to ensure that the grease is distributed evenly.





f. Loosen rack guide cap 170 (approximately 5.0 mm at the perimeter of the cap).





g. Using SST 09616-00010-02, cycle steering rack from lock to lock 2 times. This will configure the rack guide seat to the steering rack.

h. Return rack to center position (approximately 1.75 turns from lock).





4. Adjust Total Preload. Using SST 09616-00010-02 and a torque wrench, inspect the steering rack Total Preload.

NOTE:
When Checking the Steering Rack Total Preload:

^ Measure the torque during the rotation of the steering rack pinion shaft (control valve shaft), not the initial torque to start rack movement.

^ Measure the torque at the Steering Rack center point (approximately 175 turns from lock), making sure that there is smooth rotation from lock to lock.

^ Measure the torque in both directions of the rotation and average the readings to arrive at a total reading.

Adjust the rack guide cap using SST 09612-10022-02 until the Total Preload is within specification.

Torque: 14.2-18.6 in-lb. (16-21 kgfcm, 1.6-2.1 Nm).

CAUTION:
Total Preload is critical to steering feel. It is important that this procedure be followed accurately.





5. Install Rack Guide Cap Lock Nut.

a. Clean the threads of lock ring.

b. Apply LOCTITE 242(R) or equivalent to lock ring threads.

c. Hold rack guide cap in position with SST 09612-10022-02.

d. Install and tighten lock ring using SST 09922-10010.

Torque: 38 ft-lb (521 kgfcm, 51 Nm)

Confirm Total Preload to ensure it is within specification (see step 4).

Torque: 14.2-18.6 in-lb. (16-21 kgfcm, 1.6-2.1 Nm). Adjust Total Preload if necessary.





6. Install modified steering rack mounting bushings.

a. Remove original steering rack mounting bushings and install modified steering rack mounting bushings.

CAUTION:
A light film of soapy water can be applied to the new bushings for ease of installation (do not use petroleum- or paraffin-based lubricants as they will cause damage to the bushings).

NOTE:
Use SST 09951-07100-01 and a hydraulic press to remove and install bushings.

b. Match the alignment marks on the bushings with the lateral direction of the vehicle. There is no difference in the bushing end flanges. Either end can be installed first.

NOTE:
The orientation of the new bushings to the steering rack housing is the same as the original.

7. Reinstall power steering gear as described in the Repair Manual (page SR-56). Use new gaskets at the pressure tube fittings.

NOTE:
Confirm that the fluid level is full.

8. Check vehicle alignment. Set toe to specification in the Repair Manual (page SA-4).

9. Road test the vehicle for steering flutter.