Part 1 of 2
Steering GearboxREMOVAL
1. Disconnect battery ground cable.
2. Loosen front wheel nut.
3. Lift vehicle and remove front wheels.
4. Remove front exhaust pipe assembly.
WARNING: Be careful, exhaust pipe is hot.
5. Using a puller, remove tie-rod end from knuckle arm after pulling off cotter pin and removing castle nut.
6. Remove jack-up plate and front stabilizer.
7. Remove one pipe joint at the center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning steering wheel fully clockwise and counterclockwise. Discharge fluid similarly from the other pipe.
8. Remove universal joint.
9. Disconnect pipes C (Pressure pipe assembly) and D (Return pipe assembly) from pipe of gearbox.
CAUTION: Be careful not to damage these pipes.
NOTE: Disconnect upper pipe D (Return hose assembly) first, and lower pipe C (Pressure hose assembly) second.
10. Remove clamp bolts securing gearbox to crossmember, and remove gearbox.
INSTALLATION
1. Insert gearbox into crossmember, being careful not to damage gearbox boot.
2. Tighten gearbox to crossmember bracket via clamp with bolt to the specified torque.
Tightening torque: 59 Nm (6.0 kgf-cm, 43 ft. lbs.)
3. Connect pipes C and D to pipe of gearbox.
NOTE: Connect lower pipe C first, and upper pipe D second.
CAUTION: Be careful not to damage these pipes.
4. Install universal joint.
5. Connect tie-rod end and knuckle arm, and tighten with castle nut. Fit cotter pin into the nut and bend the pin to lock.
Castle nut tightening torque: Tighten to 27.0 Nm (2.75 kgf-cm, 19.9 ft. lbs.), and tighten further within 60° until cotter pin hole is aligned with a slot in the nut.
CAUTION: When connecting, do not hit cap at the bottom of tie-rod end with hammer.
6. Install front stabilizer to vehicle.
7. Install front exhaust pipe assembly.
8. Install tires.
9. Tighten wheel nuts to the specified torque.
Tightening torque: 88 Nm (9.0 kgf-cm, 65 ft. lbs.)
10. Connect battery ground cable.
11. Pour fluid into oil tank, and bleed air.
12. Check for fluid leaks.
13. Install jack-up plate.
WARNING: Be careful, exhaust manifold is hot.
14. Lower vehicle.
15. Check fluid level in oil tank.
16. After adjusting toe-in and steering angle, tighten lock nut on tie-rod end.
Tightening torque: 83 Nm (8.5 kgf-cm, 61.5 ft. lbs.)
CAUTION: When adjusting toe-in, hold boot as shown to prevent it from being rotated or twisted. If twisted, straighten it.
DISASSEMBLY
RACK HOUSING ASSEMBLY
1. Disconnect four pipes from gearbox.
2. Secure gearbox removed from vehicle in vise using ST. ST 926200000 STAND
CAUTION: Secure the gearbox in a vise using the ST as shown. Do not attempt to secure it without this ST.
3. Remove tie-rod end and lock nut from gearbox.
4. Remove small clip from boot using pliers, and move boot to tie-rod end side.
5. Remove boot with large clips.
6. Extend rack approximately 40 mm (1.57 inch) out. Unlock lock wire at lock washer on each side of tie-rod end using a standard screwdriver.
CAUTION: Be careful not to scratch rack surface as oil leaks may result.
7. Using ST, loosen lock nut.
ST 926230000 SPANNER
8. Tighten adjusting screw until it no longer tightens.
9. Using a wrench [32 mm (1.26 inch) width across flats] or adjustable wrench, remove tie-rod.
CAUTION:
^ Check ball joint for free play, and tie-rod for bends. Replace if necessary.
^ Check dust seals used with tie-rod end ball joint for damage or deterioration. Replace if necessary.
10. Loosen adjusting screw and remove spring and sleeve.
CAUTION: Replace spring and/or sleeve if damaged.
11. Remove two bolts securing valve assembly.
12. Carefully draw out input shaft and remove valve assembly.
13. Using a sharp pointed pliers, rotate the rack stopper in the direction of the arrow until the end of the circlip comes out of the stopper. Rotate the circlip in the opposite direction and pull it out.
14. Pull rack assembly from cylinder side, and draw out rack bushing and rack stopper together with rack assembly.
CAUTION: Be careful not to contact rack to inner wall of cylinder when drawing out. Any scratch on cylinder inner wall will cause oil leakage.
15. Remove rack bushing and rack stopper from rack assembly.
CAUTION: Do not reuse removed rack bushing and circlip.
16. Insert ST from pinion housing side and remove oil seal using a press.
ST 34199AE050 OIL SEAL REMOVER
NOTE: Discard removed oil seal.
CONTROL VALVE ASSEMBLY
NOTE: Parts requiring replacement are described in the smallest unit of spare parts including damaged parts and spare parts damaged. In actual disassembly work, accidental damage as well as inevitable damage to some related parts must be taken into account, and spare parts for them must also be prepared. However, it is essential to pinpoint the cause of trouble, and limit the number of replacement parts as much as possible.
1. Using ST, loosen lock nut.
ST 926230000 SPANNER
2. Tighten adjusting screw until it no longer tightens.
3. Remove two bolts securing valve assembly.
4. Carefully draw out input shaft and remove valve assembly.
5. Draw out pinion and valve assembly from valve housing, using pipe of I.D. 44 to 46 mm (1.73 to 1.81 inch) and a press.
6. Pry off dust seal using screwdriver.
7. Remove snap ring using snap ring pliers.
8. Pry off oil seal using screwdriver.
CAUTION: After removing, check inside surface of valve housing for damage. If oil seal contacting surface is damaged, replace valve housing with a new one.
9. Remove snap ring using snap ring pliers.
CAUTION:
^ Do not reuse removed snap ring.
^ Be careful not to scratch pinion and valve assembly.
10. Press out bearing together with backing washer using pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555 inch) and press.
CAUTION: Do not reuse removed bearing.
11. Remove oil seal.
CAUTION: Do not reuse removed oil seal.