Assembly
The content of this article reflects the contents of manual update 18-130-08 dated 07/03/08.
ASSEMBLY
RACK HOUSING ASSEMBLY
1) Using a press, install the bushing to gearbox installation portion.
2) Insert the ST to rack.
ST 34199XA010 GUIDE 44
3) Install the seal ring to piston portion of rack.
4) Using the ST, form the seal ring properly.
ST1 34199XA020 FORMER PISTON 44
ST2 34199AG060 GUIDE G (26)
5) Using the STB and STC, attach the oil seal to STA.
ST 34199FE040 INSTALLER A, B, C
NOTE:
Face the oil seal in the direction as shown in the figure.
6) Insert the STA with oil seal assembled from the gear side of rack. Remove the oil seal from STA near piston, and then remove the STA from rack.
7) Install the back-up washer from the gear side of rack.
8) Check the threaded end of holder and gearbox cylinder end for burrs, damage, etc. Correct if faulty.
9) Apply a coat of grease to the grooves in rack, sliding surface of sleeve and sealing surface of piston. Then insert the rack into steering body from cylinder side.
10) Attach the ST on gearbox cylinder.
ST 34199XA000 INSTALLER 44
11) Set the ST to the end of rack.
ST 34199XA030 INSTALLER & REMOVER 44
12) Using a press, press-fit until the groove of ST1 is aligned to the end surface of ST2.
ST1 34199XA030 INSTALLER & REMOVER 44
ST2 34199XA000 INSTALLER 44
13) Remove the ST.
14) Insert the outer side oil seal into the rack using the same procedure as steps 5) and 6).
ST 34199FE040 INSTALLER A, B, C
15) Make the ST and the pipe through the rack, and then press-fit the outer side oil seal using a press.
ST 34199XA000 INSTALLER 44
16) Secure the gearbox in a vise using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
17) Tighten the holder.
Tightening torque:
85 N-m (8.7 kgf-m, 62.7 ft-lb)
18) Using the ST, crimp so that the diameter of punch hole is 2 - 2.5 mm (0.08 - 0.10 in) and is aligned to the position of 2 mm (0.08 in) from gearbox cylinder end surface.
ST1 34099FA060 PUNCH HOLDER
ST2 34199XA050 BASE
19) Put a vinyl tape around the spline portion and apply genuine grease to the dust cover and install to valve assembly.
CAUTION:
Be sure to install the dust cover to groove of shaft.
20) Apply the genuine grease to the pinion gear and bearing of valve assembly.
21) Install a new gasket on valve assembly. Insert the valve assembly into place while facing the rack teeth toward pinion.
22) Tighten the bolts alternately to secure the valve assembly.
Tightening torque:
20 N-m (2.0 kgf-m, 14.8 ft-lb)
CAUTION:
Be sure to alternately tighten the bolts.
23) Temporarily install the tie-rod to rack end, and then operate the rack from lock to lock for two or three times to make it fit in.
CAUTION:
Operating the rack from lock to lock without installing tie-rods may damage the oil seal. Always install the left and right tie-rods.
24) Apply liquid gasket to more than 1/3 of entire perimeter of adjusting screw thread.
Liquid gasket:
THREE BOND 1141
25) Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert the sleeve into steering body.
Charge the adjusting screw with grease, and then insert the spring into adjusting screw. Then install on the steering body.
26) Tighten the adjusting screw to the specified torque.
Tightening torque:
5.9 N-m (0.6 kgf-m, 4.4 ft-lb)
27) Tighten the adjusting screw to the specified torque, then loosen it 20°.
28) Remove the tie-rod.
29) Adjust the turning resistance of gearbox using adjusting screw so that it is within specification.
30) Apply liquid gasket to lock nut and install it into adjusting screw. While holding the adjusting screw with wrench, tighten the lock nut using ST.
Liquid gasket:
THREE BOND 1141
ST 926230000 SPANNER
Tightening torque (lock nut):
25 N-m (2.5 kgf-m, 18.4 ft-lb)
NOTE:
Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
31) Extend the rack approx. 40 mm (1.57 in) from steering body.
32) Install the tie-rod and new lock washer into rack.
Tightening torque:
128 N-m (13.1 kgf-m, 94.4 ft-lb)
33) Bend the lock washer and crimp it.
CAUTION:
Be careful not to scratch the rack when crimping lock washer.
34) Apply a coat of grease to the tie-rod groove, and then install the boot to the housing.
NOTE:
Make sure that the boot is installed without unusual inflation or deflation.
35) Install a new boot band. Using band clamp pliers, crimp it so that the clearance of crimping portion becomes 2 mm (0.079 in) or less.
36) Fix the boot end with small clip.
37) After installing, check that the boot end is installed to the groove of the tie-rod.
38) If the tie-rod end has been removed, screw in lock nut and tie-rod end to the screwed portion of tie-rod, and tighten the lock nut temporarily in a position as shown in the figure.
Installed tie-rod length L:
28 mm (1.1 in)
39) Inspect the gearbox as follows:
Holding the "A" tie-rod end, repeat movement from lock to lock two or three times as quickly as possible.
Holding the "B" tie-rod end, turn a few times as slowly as possible.
Finally, make sure that the boot is installed in the specified position without inflating.
40) Remove the gearbox from ST
ST1 926200000 STAND
ST2 34199AG000 BOSS D
41) Install the four pipes on gearbox.
1) Connect the pipes A and B to the four pipe joints of gearbox.
Tightening torque:
Refer to the component parts. [1][2]Diagrams
2) Connect the pipes C and D to gearbox.
Tightening torque:
Pipe C:
37 N-m (3.8 kgf-m, 27.3 ft-lb)
Pipe D:
29 N-m (3.0 kgf-m, 21.4 ft-lb)
CONTROL VALVE ASSEMBLY
Specified steering grease:
VALIANT GREASE M2 (Part No. 003608001)
1) Clean all parts and tools before reassembling.
2) Apply a coat of specified power steering fluid to the inner wall of valve housing.
3) Apply grease to the oil seal.
4) Verify the direction of oil seal.
5) Using the ST and a press, install the oil seal and the bushing in valve housing.
ST 34199AG090 INSTALLER & REMOVER
6) Apply vinyl tape to the groove of pinion.
7) Install the back-up ring and oil seal to pinion, and then remove the vinyl tape.
8) Attach the ST to pinion, and install the seal ring.
ST 34199AG020 GUIDE
9) Remove the ST GUIDE, and form the seal ring properly using ST FORMER.
ST 34199AG070 FORMER
10) Put vinyl tape around pinion shaft spline to protect oil seal from damage.
11) Install the valve to pinion, and install the snap ring.
12) Attach the pinion and valve assembly into the valve housing.
13) Using the ST and a press, push the outer race of bearing and press-fit the pinion and valve assembly into housing.
ST 34199XA020 FORMER PISTON 44
14) Apply the specified grease to dust cover.
15) Install the dust cover on valve assembly.
CAUTION:
Be sure to install the dust cover to groove of shaft.
16) Apply the genuine grease to the pinion gear and bearing of valve assembly.
17) Install new O-ring to valve assembly.
18) Insert the valve assembly into place while facing the rack teeth toward pinion.
19) Tighten the bolts alternately to secure the valve assembly.
Tightening torque:
20 N-m (2.0 kgf-m, 14.8 ft-lb)
CAUTION:
Be sure to alternately tighten the bolts.
20) Apply liquid gasket to more than 1/3 of entire perimeter of adjusting screw thread.
Liquid gasket:
THREE BOND 1141 (Part No. 004403006)
21) Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert the sleeve into steering body.
Charge the adjusting screw with grease, and then insert the spring into adjusting screw. Then install on the steering body.
22) Tighten the adjusting screw to the specified torque.
Tightening torque:
5.9 N-m (0.6 kgf-m, 4.4 ft-lb)
23) Tighten the adjusting screw to the specified torque, then loosen it 20°.
24) Adjust the turning resistance of gearbox using adjusting screw so that it is within specification.
25) Apply liquid gasket to lock nut and install it into adjusting screw. While holding the adjusting screw with wrench, tighten the lock nut using ST.
Liquid gasket:
THREE BOND 1141 (Part No. 004403006)
ST 926230000 SPANNER
Tightening torque (lock nut):
25 N-m (2.5 kgf-m, 18.4 ft-lb)
NOTE:
Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
26) Remove the gearbox from ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
27) Install the four pipes on gearbox.
1) Connect the pipes A and B to gearbox.
Tightening torque:
Refer to the component parts. [1][2]Diagrams
2) Connect the pipes C and D to gearbox.
Tightening torque:
Pipe C:
37 N-m (3.8 kgf-m, 27.3 ft-lb)
Pipe D:
29 N-m (3.0 kgf-m, 21.4 ft-lb)
