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Steering Gear: Service and Repair

STEERING GEAR (for 2WD)

COMPONENTS (Part 1):




COMPONENTS (Part 2):





REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. SEPARATE CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER
5. REMOVE ENGINE UNDER COVER NO.2





6. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER
(a) Remove the 4 bolts and the front suspension member protector lower.





7. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY NO.2
(a) Fix the steering wheel with the seat belt in order to prevent rotation.

HINT:
This operation is useful to prevent damage to the spiral cable.





(b) Loosen bolt (A) and remove bolt (B), then slide the steering intermediate shaft assembly No.2.

HINT:
^ Do not remove bolt (A).
^ Do not disconnect the steering intermediate shaft assembly No.2 from the power steering link assembly.

(c) Put matchmarks on the steering intermediate shaft assembly No.2 and the power steering link assembly.
(d) Separate the intermediate shaft assembly No.2 from the power steering link assembly.
8. SEPARATE TIE ROD END LH
(a) Remove the clip and the castle nut.





(b) Using SST, separate the tie rod end LH from the steering knuckle.
SST 09628-00011

NOTICE:
^ Hang SST with a string, etc. to prevent it from falling.
^ Do not damage the front disc brake dust cover.
^ Do not damage the ball joint dust cover.
^ Do not damage the steering knuckle.

9. SEPARATE TIE ROD END RH
SST 09628-00011

HINT:
Perform the same procedure as for the LH side.





10. REMOVE POWER STEERING LINK ASSEMBLY
(a) Remove bolt (A) to disconnect the earth wire from the bracket.
(b) Remove the 2 clamps to disconnect the wire harness from the bracket.
(c) Disconnect 2 connectors (C) and (D) from the power steering link assembly.
(d) Release the lock of connector (E) and disconnect connector (E) from the power steering link assembly.
(e) Remove bolt (B) and the power steering earth wire from the power steering link assembly.





(f) Remove the 2 bolts, 2 washers, 2 nuts, and the power steering link assembly from the front suspension cross member.


DISASSEMBLY





1. FIX POWER STEERING LINK ASSEMBLY
(a) Using SST, secure the power steering link assembly.
SST 09612-00012

HINT:
Tape the SST before use.





2. REMOVE TIE ROD END LH
(a) Put matchmarks on the tie rod end LH and the steering rack end sub-assembly.
(b) Loosen the lock nut, and remove the tie rod end LH and the lock nut.
3. REMOVE TIE ROD END RH

HINT:
Perform the same procedure as for the LH side.

4. REMOVE STEERING RACK BOOT CLIP
(a) Using pliers, remove the 2 steering rack boot clips.





5. REMOVE STEERING RACK BOOT NO.1 CLAMP
(a) Using pliers and a screwdriver, remove the steering rack boot No.1 clamp (LH side) as shown in the illustration.

NOTICE:
Be careful not to damage the boot.

(b) Remove the RH side by using the same procedure as for the LH side.
6. REMOVE STEERING RACK BOOT NO.1
(a) Remove the 2 steering rack boot No. 1.





7. REMOVE STEERING RACK END SUB-ASSEMBLY
(a) Using a screwdriver and a hammer, unstake the RH and LH claw washers.

NOTICE:
Avoid any impact to the steering rack.





(b) Using SST, remove the steering rack end sub-assembly (LH side) and the claw washer.
SST 09922-10010

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





(c) Using SST, remove the steering rack end sub-assembly (RH side) and the claw washer.
SST 09922-10010

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

HINT:
Using SST, hold the rack and remove the steering rack end sub-assembly.

INSPECTION
1. INSPECT TOTAL PRELOAD
(a) Temporarily install the left and right steering rack ends to prevent steering rack over stroke.





(b) Using SST and a torque wrench, inspect preload.
SST 09616-00011
Preload (turning):
1.0 to 2.0 N*m (10.2 to 20.4 kgf*cm, 8.9 to 17.7 in.*lbf)
If turning torque is not as specified, replace the power steering link assembly.

REASSEMBLY

NOTICE:
When installing, coat the parts indicated by arrows with silicon grease.

1. INSTALL STEERING RACK END SUB-ASSEMBLY
(a) Install 2 new claw washers.

HINT:
Align the claws of the claw washer with the steering rack grooves.





(b) Using SST, install the steering rack end sub-assembly (RH side).
SST 09922-10010
Torque: 76 N*m (775 kgf*cm, 56 ft.*lbf)

NOTICE:
^ Use SST 09922-10010 following the direction shown in the illustration.
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).

HINT:
Using SST, hold the steering rack and install the steering rack end sub-assembly.





(c) Using SST, install the steering rack end sub-assembly (LH side).
SST 09922-10010
Torque: 76 N*m (775 kgf*cm, 56 ft.*lbf)

NOTICE:
^ Use SST 09922-10010 following the direction shown in the illustration.
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).

HINT:
Using SST, hold the steering rack and install the steering rack end sub-assembly.





(d) Using a brass bar and a hammer, stake the 2 claw washers.

NOTICE:
Avoid any impact to the steering rack.





2. INSTALL STEERING RACK BOOT NO.1
(a) Apply silicon grease to the inside of the small opening of the steering rack boot No.1 (LH side).





(b) Temporarily install a new steering rack boot No.1 clamp to the large opening of the steering rack boot No.1 (LH side) at the position shown by arrow (A).

NOTICE:
^ Use a new steering rack boot No.1 clamp.
^ Do not expand the steering rack boot No.1 clamp more than necessary for installation.
^ Do not deform the steering rack boot No.1 clamp.
^ Tightening force of the steering rack boot No.1 clamp becomes uneven if it is installed after being expanded as shown in the illustration. As a result, rust is caused by water entering from the clearance between the boot and rack housing, causing a malfunction.
^ Use only the supply parts which are applicable to the vehicle to secure the boot.

HINT:
After disengaging the claw of a new steering rack boot No.1 clamp, temporarily install it from the end without expanding the clamp diameter more than necessary.

(c) Install the rack boot No.1 (LH side) to the groove on the rack housing.

NOTICE:
^ Be careful not to damage or twist the boot.
^ Do not damage the steering rack boot No.1 (LH side).
^ Ensure that the steering rack boot No.1 clamp is installed before installing the steering rack boot No.1 (LH side) to the rack housing.

(d) Install the RH side by using the same procedure as for the LH side.





3. INSTALL STEERING RACK BOOT NO.1 CLAMP
(a) Using pliers and a screwdriver, install the steering rack boot No.1 clamp (LH side).

NOTICE:
^ Be careful not to damage the steering rack boot.
^ Do not twist the steering rack boot.

HINT:
Make sure that the protrusion of the steering rack boot clamp is positioned within the shown in the illustration.

(b) Install the RH side by using the same procedure as for the LH side.
4. INSTALL STEERING RACK BOOT CLIP
(a) Using pliers, install the 2 boot clips.





(b) Using SST, turn the pinion and check that the rack boots expand and contract smoothly.
SST 09616-00011





5. INSTALL TIE ROD END LH
(a) Install the lock nut and the tie rod end to the rack end until the matchmarks are aligned.

HINT:
After adjusting toe-in, torque the lock nut.

6. INSTALL TIE ROD END RH

HINT:
Perform the same procedure as for the LH side.

INSTALLATION





1. INSTALL POWER STEERING LINK ASSEMBLY
(a) Install the power steering link assembly with the 2 bolts, 2 wasters and 2 nuts.
Torque: 118 N*m (1,200 kgf*cm, 87 ft.*lbf)





(b) Install the power steering earth wire to the power steering link assembly with bolt (B).
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(c) Connect wire harness connector (E) to the power steering link assembly and securely lock the connector.
(d) Connect 2 wire harness connectors (C) and (D) to the power steering link assembly.
(e) Install the 2 wire harness clamps to the power steering link assembly.
(f) Connect the earth wire to the bracket with bolt (A).
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
2. CONNECT TIE ROD END LH
(a) Connect the tie rod end LH to the steering knuckle with the nut.
Torque: 65 N*m (663 kgf*cm, 50 ft.*lbf)
(b) Install a new clip.

NOTICE:
If the holes for the clip are not aligned, tighten the nut up to 60° further.

3. CONNECT TIE ROD END RH

HINT:
Perform the same procedure as for the LH side.





4. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY NO.2
(a) Align the matchmarks on the intermediate shaft assembly No.2 and the power steering link assembly.





(b) Install bolt (A) and tighten the 2 bolts.
Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf)





5. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER
(a) Install the front suspension member protector lower to the front suspension cross member with the 4 bolts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
6. INSTALL ENGINE UNDER COVER NO.2
7. INSTALL ENGINE UNDER COVER
8. INSTALL FRONT WHEELS
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
11. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
12. PERFORM INITIALIZATION
Some systems need initialization when disconnecting the cable from the negative battery terminal.
13. INITIALIZE ROTATION ANGLE SENSOR AND CALIBRATE TORQUE SENSOR ZERO POINT
14. PERFORM VARIABLE GEAR RATIO STEERING SYSTEM CALIBRATION

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