Overhaul
DISASSEMBLY1. RACK HOUSING ASSEMBLY
1. Disconnect the four pipes from gearbox.
NOTE: Remove the pipes C and D, which are fixed to clamp plate, as a unit.
2. Secure the gearbox removed from vehicle in a vise using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
CAUTION: Secure the gearbox in a vise using ST as shown in the figure. Do not secure the gearbox without this ST.
3. Remove the tie-rod end and lock nut from gearbox.
4. Remove the small clip from the boot using pliers, and then move the boot to tie-rod end side.
5. Using a flat tip screwdriver, remove the band from boot.
NOTE: Replace the boot if there is damage, cracks or deterioration.
6. Using the ST, loosen the lock nut.
ST 926230000 SPANNER
7. Tighten the adjusting screw until it can no longer be tightened.
8. Remove the tie-rod using ST.
ST 926230000 SPANNER
9. Loosen the adjusting screw, and remove the spring and sleeve.
10. Remove the two bolts securing valve assembly.
11. Carefully draw out the input shaft and remove the valve assembly.
12. Using a drill, release the crimping of holder.
CAUTION: Make a hole of 2 mm (0.08 in) depth using a drill with 3 mm (0.12 in) diameter.
13. Remove the holder.
14. Attach the ST to the pinion housing side of the rack, and push out the rack together with the outer side oil seal.
ST 34199FE000 INSTALLER & REMOVER
NOTE: Block the pipe connection of steering body to prevent fluid from flowing out.
15. Insert the ST from pinion housing side and remove the oil seal using a press.
ST 34099FA140 OIL SEAL REMOVER
16. Using a press, remove the bushing of gearbox installation portion.
2. CONTROL VALVE
1. Disconnect the pipes A and B from gearbox.
2. Secure the gearbox removed from vehicle in a vise using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
CAUTION: Secure the gearbox in a vise using ST as shown in the figure. Do not secure the gearbox without this ST.
3. Using the ST, loosen the lock nut.
ST 926230000 SPANNER
4. Tighten the adjusting screw until it can no longer be tightened.
5. Loosen the adjusting screw, and remove the spring and sleeve.
6. Remove the two bolts securing valve assembly.
7. Carefully draw out the input shaft and remove the valve assembly.
8. Put a vinyl tape around the spline portion, and slide the dust cover to remove.
9. Using a press, remove the pinion & valve assembly from valve housing.
10. Using the ST and a press, remove the bushing and oil seal from the valve housing.
ST 34199AGO90 INSTALLER & REMOVER
CAUTION:
- Do not apply a force to the end surface of valve housing.
- Do not reuse the oil seal after removal.
11. Using a snap ring pliers, remove the snap ring, valve, oil seal and back-up washer.
CAUTION: Be careful not to scratch the pinion and valve assembly.
ASSEMBLY
1. RACK HOUSING ASSEMBLY
1. Using a press, install the bushing to gearbox installation portion.
2. Insert the ST to rack.
ST 34199AGO30 GUIDE
3. Install the seal ring to piston portion of rack.
4. Using the ST, form the seal ring properly.
ST1 34199AG080 FORMER PISTON
ST2 34199AG050 GUIDE G (24)
5. Attach the ST to the teeth of rack assembly, and insert the oil seal into the rack.
ST 926390001 COVER & REMOVER
6. Remove the ST from the rack assembly.
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. Temporarily tighten a new holder to the gearbox cylinder.
11. Put a mark at the specified position measured from the end surface of ST, as shown in the figure.
Specified position:
Except for 2.5 GT-B and 3.0 R-L TD: 13.5 mm (0-53 in)
2.5 GT-B and 3.0 R-LTD: 18.9 mm (0.74 in)
ST 34199FE000 INSTALLER & REMOVER
12. Set the ST to the end of rack.
ST 34199FE000 INSTALLER & REMOVER
13. Using a press, press-fit until the mark on ST is aligned to the end surface of holder.
14. Remove the ST and holder.
15. Insert the outer side oil seal into the rack using the same procedure as steps 5.and 6).
ST 926390001 COVER & REMOVER
16. Make the ST and the pipe through the rack, and then press-fit the outer side oil seal using a press.
ST 34199AG010 INSTALLER
17. Secure the gearbox in a vise using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
18. Tighten a new holder.
Tightening torque: 70 N-m (7.1 kgf-m, 51.6 ft-lb)
19. 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 34199FE020 BASE
20. 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.
21. Apply the genuine grease to the pinion gear and bearing of valve assembly.
22. Install a new gasket on valve assembly. Insert the valve assembly into place while facing the rack teeth toward pinion.
23. 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.
24. 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.
25. Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.
Liquid gasket. THREE BOND 1141
26. 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.
27. Tighten the adjusting screw to the specified torque, then loosen it.
Tightening torque: 25 N-m (2.5 kgf-m, 18.4 ft-lb)
28. Tighten the adjusting screw to the specified torque, then loosen it 200.
Tightening torque: 3.9 N-m (0.4 kgf-m, 2.9 ft-lb)
29. Remove the tie-rod.
30. Adjust the adjustment screw until the rotational resistance of gearbox is within specifications.
31. 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.
32. Extend the rack approx. 40 mm (1.57 in) from steering body.
33. Install the tie-rod and new lock washer into rack.
Tightening torque: 90 N-m (9.1 kgf-m, 65.8 ft-lb)
34. Bend the lock washer and crimp it.
CAUTION: Be careful not to scratch the rack when crimping lock washer.
35. Apply a coat of grease to the tie-rod groove, and then install the boot to the housing.
CAUTION: Right side boot has groove for identification, be sure to install the right and left of boot.
NOTE: Make sure that the boot is installed without unusual inflation or deflation.
36. 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.
37. Fix the boot end with small clip.
38. After installing, check that the boot end is installed to the groove of the tie-rod.
39. 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: 31 mm (1.22 in)
40. 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.
41. Remove the gearbox from ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
42. 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.
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)
2. 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 a press, push the outer race of bearing and press-fit the pinion & valve assembly into housing.
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 1/3 or more 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, then loosen it.
Tightening torque: 25 N-m (2.5 kgf-m, 18.4 ft-lb)
23. Tighten the adjusting screw to the specified torque, then loosen it 20°.
Tightening torque: 3.9 N-m (0.4 kgf-m, 2.9 ft-lb)
24. Adjust the adjustment screw until the rotational resistance of gearbox is within specifications.
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
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.
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)
INSPECTION
1. BASIC INSPECTION
1. Clean all the disassembled parts, and check for wear, damage or any other faults, then repair or replace as necessary.
2. When disassembling, check the inside of gearbox for water. If any water is found, carefully check the boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts.
2. SERVICE LIMIT
Make a measurements as follows. If it exceeds the specified service limits, adjust or replace.
NOTE: When making a measurement, vise the gearbox using ST. Never vise the gearbox by inserting aluminum plates etc. between vise and gearbox.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
3. RACK SHAFT PLAY IN THE RADIAL DIRECTION
Right-turn steering:
Service limit: 0.12 mm (0.005 in) or less
On condition
Weighting point
L1: 10 mm (0.39 in)
P: 98 N (10 kgf, 22 lb)
Measuring point
L2: 25 mm (0.98 in)
4. INPUT SHAFT PLAY
In radial direction:
Service limit: 0.26 mm (0.01 in) or less
On condition
P: 98 N (10 kgf, 22 lb)
5. TURNING RESISTANCE OF GEARBOX
Using the ST, measure the gearbox turning resistance.
ST 34099PA100 SPANNER
Service limit. Maximum allowable resistance: 11.3 N (1.15 kgf, 2.54 lb) or less.
Difference between right and left turning resistance: 24% or less
6. OIL LEAKAGE
1. Lift up the vehicle.
2. If a fluid leak is found, clean the fluid completely from the suspect area, and turn the steering wheel approx. 30 to 40 times to the left and right from lock to lock, with the engine running, and check again for leaks immediately, and also after a few hours have passed.
3. Cause and solution for oil leakage from "a"
The oil seal is damaged. Replace the valve assembly with a new part.
4. Cause and solution for oil leakage from "b"
The torsion bar O-ring is damaged. Replace the valve assembly with a new part.
5. Cause and solution for oil leakage from "c"
The oil seal is damaged. Replace the valve assembly or oil seal with a new part.
6. Cause and solution for oil leakage from "d"
The pipe is damaged. Replace the faulty pipe or O-ring.
7. Cause and solution for oil leakage from "g".
The hose is damaged. Replace the hose with a new part.
8. If leak is other than a, b, c, d or g, or if oil is leaking from gearbox, move the right and left boots toward tie-rod end side, respectively, with the gearbox mounted to the vehicle, and remove fluid from surrounding portions. Then, turn the steering wheel from lock to lock about 30 to 40 times with the engine running, then re-inspect the leaking area immediately after and several hours after this operation.
1. Leakage from "e"
The cylinder seal is damaged. Replace the rack bushing with a new part.
2. Leakage from "f"
There are two possible causes. Perform the following step first. Remove the pipe assembly B from the valve housing, and close the circuit using ST.
ST 926420000 PLUG
Turn the steering wheel from lock to lock approx. 30 to 40 times with the engine running, then inspect the leaked portion immediately after and several hours after this operation.
- If leakage from "f" is noted again:
The oil seal of pinion and valve assembly is damaged. Replace the pinion & valve assembly with a new part. Or replace the oil seal and the parts that are damaged during disassembly with new parts.
- If oil stops leaking from "f":
The oil seal of rack housing is damaged. Replace the oil seal and parts that are damaged during disassembly with new parts.