Reassembly
1. Clean and prepare all components.Re-assembly of Valve Assembly
2. Cover area "a", where the sleeve is installed, with tape, in order to make an even surface and to prevent damage to the oil seal lip. Apply Multi-purpose Wheel Bearing Grease # 2 grade to the tape surface.
SERVICE MATERIAL:
Multi-purpose Wheel Bearing Grease # 2 grade
3. Install spacer and new pinion oil seal onto the valve assembly.
CAUTION:
The spacer is directional. The chamfer faces the pinion oil seal side of the valve assembly.
4. Remove tape.
CAUTION:
Make sure that there is no adhesive on the valve assembly.
5. Install the sleeve assembly on the valve shalt, aligning the pin on the sleeve assembly with the groove in the valve shaft, then install the new retaining ring.
Assembly of the Valve Housing
6. Multi-purpose Wheel Bearing Grease # 2 grade to the following areas.
^ External part of the new stub oil seal
^ Internal surface of the valve housing
^ Taper side of the special tool "Pinion bearing remover & installer"
SERVICE MATERIAL:
Multi-purpose Wheel Bearing Grease # 2 grade
SPECIAL TOOL:
09943-86010 Pinion bearing remover
& installer
7. Place a new stub oil seal and the ball bearing on the special tool Pinion bearing remover & installer, position them in the valve housing by hand. Then press-fit them with a press.
SPECIAL TOOL
09943-86010 Pinion bearing remover & installer
CAUTION:
^ Make sure there is no damage on the external surface of the special tool, or the seal may be damaged.
^ There is a direction for the stub oil seal to fit. Refer to illustration.
^ Do not damage internal surface of valve housing when inserting the special tool.
8. Apply Multi-purpose Wheel Bearing Grease # 2 grade to the inside of the stub oil seal.
SERVICE MATERIAL:
Multi-purpose Wheel Bearing Grease # 2 grade
Re-assembly of Steering Gear
9. Apply Multi-purpose Wheel Bearing Grease # 2 to the external surface of the special tool "Pinion oil seal protector" and place on the input side of the valve assembly.
CAUTION:
Make sure there is no damage on the external surface of the special tool that may damage the oil seal.
SERVICE MATERIAL:
Multi-purpose Wheel Bearing Grease # 2 grade
10. Insert the valve assembly into the valve housing until the spacer contacts with the face of the housing.
CAUTION:
Do not damage the seal rings on the valve sleeve assembly.
11. Apply Liquid Gasket Three Bond 1105 or equivalent on the sealing surface to the valve housing.
SERVICE MATERIAL:
Permatex 90062, Liquid gasket Three Bond
1105 or equivalent
CAUTION:
Make sure there is no oil and/or dirty material on the surface of the valve housing before applying liquid gasket.
12. If a shim was removed during Steps of Disassembly, place it between the valve housing and steering shaft body.
13. Apply Multi-purpose Wheel Bearing Grease # 2 grade to the bearing of the valve housing assembly and pinion gear. Install valve housing into steering shaft body.
SERVICE MATERIAL:
Multi-purpose Wheel Bearing Grease # 2 grade
14. Alternately tighten the 2 bolts securing the valve housing to the steering shaft body.
TIGHTENING TORQUE:
19.6-29.4 Nm (14.5-21.5 lbs.ft.)
15. Make sure the steering is in a condition to go straight (centered), by turning the input shaft of the valve housing.
16. Apply liquid gasket Three Bond 1102 or equivalent on 1/3 of the threads on the plunger.
SERVICE MATERIAL:
Permatex 80019, Liquid gasket Three Bond
1102 or equivalent
17. Tighten adjusting plug in the following process.
a. Torque plunger to 4.9 Nm (3.5 lb.ft.)
b. Loosen plunger
c. Torque plunger to 4.9 Nm (3.5 lb.ft.)
d. Loosen plunger
e. Torque plunger to 4.9 Nm (3.5 lb.ft.)
f. Turn plunger counterclockwise approximately 22 degrees.
18. While holding the adjusting plug, tighten plunger lock nut to specified torque.
TIGHTENING TORQUE:
58.8-73.5 Nm (43-54 lb.ft.)
19. Make sure that the steering moves smoothly, by turning the input shaft in both directions lock to lock.
20. Install power steering hydraulic pipes and tighten nuts to specified torque.
TIGHTENING TORQUE:
Valve housing side:
15.7-23.5 Nm (11.5-17 lb.ft.)
Steering shaft body side:
19.6-27.4 Nm (14.5-20 lb.ft.)
21. Referring to the Service Manual, Re-install the steering gear in the vehicle.
Note:
Make sure the Toe-in is within specification.
Test drive vehicle to ensure the steering wheel
is straight