Disassembly and Assembly

DISASSEMBLY

NOTICE: When using a vise, do not overtighten it.





1. Secure power steering gear assembly in vise.
Using Special Service Tool (SST) 09612-00012 or equivalent, secure the power steering steering gear assembly in a vise.
2. Remove two turn pressure tubes.
a. Remove the union bolt and the two gaskets.





b. Using SST 09633-00020 or equivalent, remove the tube.
c. Remove the two union seats from the rack housing.





3. Remove right and left tie rod ends and lock nuts. Place matchmarks on the tie rod end and rack end, and loosen the lock nut.
4. Remove right and left clips, rack boots and clamps.

NOTICE:
- Be careful not to damage the boot.
- Mark the right and left boots.

5. Remove right and left rack ends and claw washers.





a. Using a chisel and a hammer, unstake the washer.

NOTICE: Avoid any impact to the steering rack.





b. Using a (22 mm) spanner to hold the steering rack and, using SST 09922-10010 or equivalent, remove the rack end.

NOTICE:
- Use SST 09922-10010 or equivalent, in the direction shown in the illustration.
- Mark the right and left rack ends.





6. Remove rack guide spring cap lock nut. Using SST 09922-10010 or equivalent, remove the nut.

NOTICE: Use SST 09922-10010 or equivalent in the direction shown in the illustration.

7. Remove rack guide spring cap, rack guide spring, rack guide and rack guide seat, as follows:
a. Using a (24 mm) hexagon wrench, remove the cap.
b. Remove the seat from the guide.
8. Remove rack housing cap.





9. Remove self-locking nut, bearing and spacer. Using SST 09616-00010 or equivalent, to stop the control valve shaft rotating, remove the nut.
10. Remove dust cover.
11. Remove control valve housing with control valve assembly.





a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
b. Using a (6 mm) hexagon wrench, remove the two bolts.
c. Remove the O-ring from the housing.





12. Remove control valve assembly. Using a plastic hammer, tap out the control valve assembly.

NOTICE: Be careful not to damage the oil seal lip.

13. Remove cylinder end stopper and spacer. Using snap ring pliers, remove the snap ring from the rack housing.
14. Remove steering rack and oil seal.





a. Using an extension bar or brass bar and a press, press out the rack with the oil seal.

NOTE: Take care not to drop the rack.

b. Remove the oil seal from the rack.





15. Remove oil seal. Using SST 09950-60010 (09951-00280), 09950-70010 (09951-07200) or equivalents, press out and remove the oil seal.

INSPECTION

NOTICE: When using a vise, do not overtighten it.

1. Inspect steering rack.





a. Using a dial indicator, check the rack for runout and for teeth wear or damage.
Maximum runout: 0.30 mm (0.0118 inch).
b. Check the back surface for wear or damage.
2. If necessary, replace oil seal and bearing.





a. Set Special Service Tool (SST) 09612-30012 or equivalent to the rack housing, as shown.
b. Turn A clockwise and engage the tips of C on the bearing.
c. Using a (8 mm) spanner, keep A fixed while turning nut B clockwise, and remove the bearing.

NOTICE: Be careful not to damage the rack housing.





d. Using SST 09612-30012 or equivalent, remove the oil seal from the rack housing.

NOTICE: Be careful not to damage the rack housing.

HINT: When using SST, apply the tips of SST to the cutouts in the rack housing.

e. Coat a new oil seal lip with power steering fluid.





f. Using SST 09950-60010 (09951-00280, 09951-00400, 09952-06010), 09950-70010 (09951-07100) or equivalents, press in the oil seal.

NOTICE: Make sure to install the oil seal facing the correct direction.





g. Using SST 09950-60010 (09951-00460), 09950-70010 (09951-07100) or equivalents, press in the bearing.
3. If necessary, replace oil seal and the bearing.





a. Using SST 09950-60010 (09951-00240), 09950-70010 (09951-07100) or equivalents, press out the oil seal with the bearing from the control valve housing.
b. Coat a new oil seal lip with power steering fluid.





c. Using SST 09950-60010 (09951-00320), 09950-70010 (09951-07200) or equivalents, press in the oil seal.

NOTICE: Make sure to install the oil seal facing the correct direction.





d. Using SST 09950-60010 (09951-00340), 09950-70010 (09951-07200) or equivalents, press in the bearing.
4. If necessary, replace teflon ring and O-ring.





a. Using a screwdriver, remove the teflon ring and the O-ring from the steering rack.

NOTICE: Be careful not to damage the groove of the ring.

b. Coat a new O-ring with power steering fluid and install it.





c. Expand a new teflon ring with your fingers.

NOTICE: Be careful not to overexpand the ring.

d. Coat the ring with power steering fluid.





e. Install the ring to the rack, and snug it down with your fingers.
5. If necessary, replace teflon rings.





a. Using a screwdriver, remove the four rings from the control valve assembly.

NOTICE: Be careful not to damage the grooves for the ring.

b. Expand the four new rings with your fingers.

NOTICE: Be careful not to overexpand the ring.

c. Coat the rings with power steering fluid.
d. Install the rings to the control valve assembly, and snug them down with your fingers.





e. Carefully slide the tapered end of SST 09631-20081 or equivalents, over the rings to seal them.

NOTICE: Be careful not to damage the rings.

6. If necessary, replace teflon rings and O-rings.





a. Using a screwdriver, remove the two teflon rings and O-rings from the control valve assembly.

NOTICE: Be careful not to damage the grooves for the teflon ring.

b. Coat two new O-rings with power steering fluid, and install them.
c. Expand two new teflon rings with your fingers.

NOTICE: Be careful not to overexpand the teflon rings.

d. Coat the rings with power steering fluid.
e. Install the rings to the valve assembly, and snug them down with your fingers.





f. Carefully slide the tapered end of SST 09631-32020 or equivalent, over the teflon rings to seal them.

NOTICE: Be careful not to damage the teflon rings.

7. If necessary, replace pressure control valve assembly.
a. Using a (6 mm) hexagon wrench, remove the three bolts and the connector bracket.
b. Remove the three O-rings from the control valve housing.
c. Coat three new O-rings with power steering fluid, and install them.
d. Using a (6 mm) hexagon wrench, install a new pressure control valve and connector bracket with the three bolts.
Torque: 18 Nm (13 ft. lbs.).

REASSEMBLY

NOTICE: When using a vise, do not overtighten it.

1. Coat 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 Special Service Tool (SST) 09950-60010 (09951-00240, 09951-00430, 09952-06010), 09950-70010 (09951-07360) or equivalents, press in the oil seal.

NOTICE:
^ Make sure to install the oil seal facing the correct direction.
^ Take care that the oil seal does not get reversed as you install it.

3. Install steering rack.





a. Install SST 09631-20102 or equivalent, to the rack.

HINT: If necessary, scrape the burrs off the rack teeth end and burnish.

b. Coat the SST with power steering fluid.
c. Install the rack into the rack housing.

NOTICE: Be careful not to damage the oil seal lip.

d. Remove the SST.
4. Install oil seal and the spacer.





a. To prevent oil seal lip damage, wind vinyl tape on the steering rack, and apply power steering fluid.
b. Coat a new oil seal lip with power steering fluid.
c. Install the oil seal by pushing it into the rack housing without tilting.

NOTICE:
- Make sure to install the oil seal facing the connect direction.
- Be careful not to damage the oil seal lip.

d. Install the spacer into the rack housing.
5. Install cylinder end stopper.





a. Using SST 09950-60010 (09951-00310), 09950-70010 (09951-07200) or equivalents, and a hammer, drive in the stopper.
b. Using snap ring pliers, install the snap ring to the rack housing.
6. Air tightness test.





a. Install SST 09631-12071 or equivalent, to the rack housing.

NOTICE: Do not install union seats.

b. Apply 53.3 kPa (15.75 inch 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. Coat the teflon rings with power steering fluid.





b. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
c. Install the valve assembly into the valve housing.

NOTICE: Be careful not to damage the teflon rings and oil seal.

8. Install control valve housing with control valve assembly.
a. Coat a new O-ring with power steering fluid and install it to the housing.
b. Using a (6 mm) hexagon wrench, torque the two bolts.
Torque: 18 Nm (13 ft. lbs.).





9. Install bearing spacer and self-locking nut. Using SST 09616-00010 or equivalent, to stop the control valve shaft rotating, torque a new nut.
Torque: 39 Nm (29 ft. lbs.).
10. Install rack housing cap.
a. Apply sealant to two or three threads of the cap.
Sealant: THREE BOND 1344 LOCTITE 242 or equivalent.
b. Torque the cap.
Torque: 69 Nm (50 ft. lbs.).
11. Install rack guide seat, rack guide, rack guide spring and rack guide spring cap.
a. Install the seat to the guide.
b. Apply sealant to two or three threads of the cap.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
c. Temporarily install the cap.
12. Adjust total preload.
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the right and left hand rack ends.
b. Using a (24 mm) hexagon wrench, torque the rack guide spring cap.
Torque: 25 Nm (18 ft. lbs.).





c. Using a (24 mm) hexagon wrench, return the cap 12°.
d. Using SST 09616-00010 or equivalent, turn the control valve shaft right and left one or two times.
e. Using a (24 mm) hexagon wrench, loosen the cap until the rack guide spring is not functioning.





f. Using SST 09616-00010 or equivalent, a torque wrench and hexagon wrench (24 mm), tighten the cap until the preload is within the specification.
Preload (turning): 1.O - 1.9 Nm (8.7 - 17.4 inch lbs.).
13. Install rack guide spring cap lock nut.
a. Apply sealant to two or three threads of the nut.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.





b. Using SST 09922-10010 or equivalent, and a (24 mm) hexagon wrench, torque the nut.
Torque: 50 Nm (37 ft.lbs.).

NOTICE: Use SST 09922-10010 or equivalent, in the direction shown in the illustration.

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

c. Recheck total preload.
Preload (turning): 1.0 - 1.9 Nm (8.7 - 17.4 inch lbs.).
d. Remove the RH and LH rack ends.
14. Install dust cover.
15. Install right and left 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 a (22 mm) spanner to hold the steering rack steady, and using SST 09922-10010 or equivalent, torque the rack end.
Torque: 77 Nm (57 ft. lbs.).

NOTICE: Use SST 09922-10010 or equivalent 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 to the rack.

16. Install right and left rack boots, clamps and the 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 turned.

b. Install the boot.

NOTICE: Be careful not to damage or twist the boot.

c. Install the clamp and clip to the boot.
17. Install right and left 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 the toe-in, torque the nut.
Torque: 56 Nm (41 ft. lbs.).
18. Install two turn pressure tubes.
a. Install the two union seats.





b. Using SST 09633-00020 or equivalent, install the tube.
Torque: 24 Nm (18 ft. lbs.).

HINT:
- Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
- This torque value is effective in case that SST is parallel to a torque wrench.

c. Torque the union bolt over two new gaskets.
Torque: 34 Nm (25 ft. lbs.)