Overhaul
Steering GearboxDISASSEMBLY
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.
CAUTION:
Secure the gearbox assembly in a vise using ST as shown. Do not secure the gearbox to the vise without this ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
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.
9) Loosen the adjusting screw, and remove the spring and sleeve.
10) Clean any dirt adhered to the input shaft. Remove the dust cover, paying attention not to scratch the housing or input shaft and not to allow foreign matter to enter gearbox interior.
CAUTION:
Roll a vinyl tape around the input shaft spline to avoid scratching the dust cover.
11) Align the ST pin with plug hole to install. Rotate the ST counterclockwise to remove plug.
ST 34199AE090 PLUG WRENCH
12) Remove the valve assembly paying attention not to scratch the seal ring or valve housing inner surfaces.
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 the valve side and press the back-up ring and oil seal out.
ST 34199FE010 REMOVER
16) Using ST1 and ST2, repair the crimped portion of cylinder.
ST1 34099FA080 PUNCH
ST2 34199FE020 BASE
17) If the cylinder edge is deformed in a convex shape, repair using an oil stone.
18) Remove the oil seal using ST and push out from the plug.
ST 34199AE100 OIL SEAL PLUG REMOVER
NOTE:
Do not apply force on the plug edge surface.
19) Set the ST at a size shown in the figure.
ST 34199AE120 GEARBOX OIL SEAL REMOVER
20) Set the stopper to gearbox, then insert the tip of the ST to the gearbox.
21) By fixing the 2-surface widths, press-in the rod while rotating it and catch the oil seal.
22) While fixing the 2-surface widths, pull out the oil seal by rotating nut.
CAUTION:
Take care not to scratch the gearbox inner surface.
ASSEMBLY
1) Apply a coat of grease to the inside and outside of the new oil seal.
Steering grease:
VALIANT GREASE M2 (Part No. 003608001)
2) Verify the direction of the oil seal and installation position. Using the ST and a press, press-fit the oil seal into the gearbox.
CAUTION:
^ Make sure to press fit the oil seal in all the way.
^ The gap between the gearbox end face and the ST is to be approximately 4 mm (0.157 in) after press fitting.
ST 34199AE130 GEARBOX OIL SEAL INSTALLER
3) Attach the steering body to ST as shown in the figure. Apply a coat of grease to needle bearing.
CAUTION:
Make sure the needle bearing is free from defects. If it is faulty, replace the steering body with a new part.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
4) Using the ST A and ST B, attach the oil seal to ST C.
ST 34199FE040 INSTALLER A, B, C
^ INSTALLER A: 34199FE070
^ INSTALLER B: 34199FE080
^ INSTALLER C: 34199FE090
NOTE:
Face the oil seal in the direction as shown in the figure.
5) Insert the ST C with oil seal assembled from the gear side of rack. Remove the oil seal from ST C near piston, and then remove the ST C from rack.
6) Install the back-up washer from the gear side of rack.
7) 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.
8) Temporarily tighten the holder to gearbox cylinder.
9) Put a mark on a location of 9 mm (0.35 in) from the ST end surface as shown in the figure.
ST 34199FE000 INSTALLER & REMOVER
10) Set the ST to the end of rack.
ST 34199FE000 INSTALLER & REMOVER
11) Using a press, press-fit until the mark on the ST is aligned with the end surface of the holder.
12) Remove the ST and holder.
13) Insert the outer side oil seal into the rack using the same procedure as steps 4) and 5).
ST 34199FE040 INSTALLER A, B, C
^ INSTALLER A: 34199FE070
^ INSTALLER B: 34199FE080
^ INSTALLER C: 34199FE090
14) Make the ST2 pass through the rack, and then press in the rack and ST2 using a press.
Press in the outer side oil seal until the ST1 and ST2 comes into contact with each other and the rack end surface is aligned to the end surface of the ST2.
ST1 34199FE050 GUIDE
ST2 34199FE060 INSTALLER
15) Install a new holder to the cylinder side of steering body.
Tightening torque:
75 Nm (7.65 kgf-m, 55.3 ft-lb)
16) Using the ST, crimp one location less than 3 mm (0.12 in) from the holder.
CAUTION:
Be careful not to deform the holder.
ST1 34099FA060 PUNCH HOLDER
ST2 34199FE020 BASE
17) Roll a vinyl tape on the serration portion of valve assembly, and then apply grease on the tape surface.
18) Apply a coat of grease on the gear teeth of the valve assembly, and then attach the valve assembly taking care not to scratch oil seal and seal ring.
19) Replace the O-rings of plug circumference with new O-rings.
20) Apply grease on the oil seal circumference, and then press it into the plug using ST and a press.
CAUTION:
^ Install the oil seal paying attention to correct direction.
^ Make sure to press fit the oil seal in all the way.
^ The gap between the plug and the ST is to be approximately 1 mm (0.039 in) after press fitting.
ST 34199AE110 OIL SEAL PLUG INSTALLER
21) Attach the plug using ST.
ST 34199AE090 PLUG WRENCH
Tightening torque:
64 Nm (6.53 kgf-m, 47.2 ft-lb)
22) Install the dust cover, and remove the vinyl tape.
23) Temporarily tighten the tie-rod to the rack end, and then operate the rack from lock to lock for two or three times to make it fit in.
CAUTION:
If operating the rack from lock to lock without installing tie-rods, it may damage the oil seal. Always install the tie-rods LH and RH.
24) Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.
Liquid gasket:
THREE BOND 1102 or THREE BOND 1215
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, then loosen it.
Tightening torque:
9.8 Nm (0.99 kgf-m, 7.2 ft-lb)
27) Tighten the adjusting screw to the specified torque, then loosen it.
Tightening torque:
4.9 Nm (0.49 kgf-m, 3.6 ft-lb)
28) Tighten the adjusting screw to the specified torque, then loosen it approx. 30°.
CAUTION:
Do not loosen 37° or more.
Tightening torque:
4.9 Nm (0.49 kgf-m, 3.6 ft-lb)
29) Remove the tie-rod.
30) Adjust the turning resistance of gearbox so that it is within specification using adjusting screw.
31) Attach the lock nut into adjusting screw, and while holding the adjusting screw with wrench, tighten the lock nut using ST.
ST 926230000 SPANNER
Tightening torque (lock nut):
39 Nm (3.98 kgf-m, 28.9 ft-lb)
NOTE:
Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
32) Install the tie-rod into rack.
Tightening torque:
90 Nm (9.18 kgf-m, 66.4 ft-lb)
NOTE:
Check the mating face of rack and tie-rod for foreign matter such as dust etc.
33) 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.
34) Using the boot clamp pliers, crimp the boot so that the clearance of the boot band crimp portion becomes 2 mm (0.08 in) or less.
NOTE:
Use a new boot band.
35) Fix the boot end with small clip.
36) After installing, check that the boot end is installed to the groove of the tie-rod.
37) 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)
38) Inspect the gearbox as follows:
"A" Holding the tie-rod end, repeat lock to lock several times as quickly as possible.
"B" Holding the tie-rod end, turn it slowly at a radius several times as large as possible.
Finally, make sure that the boot is installed in the specified position without inflating.
39) Remove the gearbox from ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
40) Attach the 4 pipes to the steering body and control valve housing.
INSPECTION
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.
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
Rack shaft sliding resistance:
Limit
314 N (32 kgf, 71 lbf) or less
Left/right differential of sliding resistance:
20% or less
RACK SHAFT PLAY IN THE RADIAL DIRECTION
Right-turn steering:
Limit
Direction white arrows black arrows
0.4 mm (0.016 in) or less
Condition
L: 5 mm (0.20 in)
P: 98 N (10 kgf, 22 lbf)
Left-turn steering:
Limit
Direction black arrows
0.6 mm (0.024 in) or less
Direction white arrows
0.4 mm (0.016 in) or less
INPUT SHAFT PLAY
In radial direction:
Service limit
0.18 mm (0.0071 in) or less
Condition
P: 98 N (10 kgf, 22 lbf)
In axial direction:
Service limit
0.27 mm (0.0106 in) or less
Condition
P: 20 - 49 N (2 - 5 kgf, 4 - 11 lbf)
TURNING RESISTANCE OF GEARBOX
Using the ST, measure the gearbox turning resistance.
ST 34099PA100 SPANNER
Service limit:
Maximum allowable resistance:
13 N (1.3 kgf, 2.9 lbf) or less
Difference between right and left turning resistance:
20% or less
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 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 or oil seal with a new part.
4) Cause and measure for oil leakage from "b".
The torsion bar O-ring is damaged. Replace the valve assembly with a new part.
5) Cause and measure for oil leakage from "c".
The oil seal is damaged. Replace the oil seal with a new part.
6) Cause and solution for oil leakage from "d".
The pipe is damaged. Replace the faulty pipe or Oring.