Disassembly and Reassembly

DISASSEMBLY

NOTICE: When using a vise, do not overtighten it.





1. REMOVE 2 TURN PRESSURE TUBES
a. Using Special Service Tool (SST), remove the 2 turn pressure tubes.
SST 09023-38400
b. Remove the 4 O-rings from the tubes.





2. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, 2 bolts and nuts, secure the gear assembly in a vise, as shown in the illustration.
SST 09612-00012
Reference:
Bolt: 90105-10346
Nut: 90170-10198

HINT: Use 2 of the same type of SST.





3. REMOVE RIGHT-HAND AND LEFT-HAND TIE ROD ENDS AND LOCK NUTS
a. Place matchmarks on the tie rod end, lock nut and rack end.
b. Loosen the lock nut, remove the tie rod end and lock nut.
c. Employ the same manner described above to the other side.





4. REMOVE RIGHT-HAND AND LEFT-HAND CLIPS, RACK BOOTS AND CLAMPS
a. Using a screwdriver, loosen the 2 clamps.
b. Remove the 2 clips and boots.

HINT: Mark the Right-Hand and Left-Hand boots.

NOTICE: Be careful not to damage the boot.

5. REMOVE RIGHT-HAND AND LEFT-HAND RACK ENDS AND CLAW WASHERS





a. Using a screwdriver and hammer, unstake the washer.

NOTICE: Avoid any impact on the steering rack.





b. Using a spanner to hold the steering rack steadily, and using SST, remove the rack end.
SST 09922-10010

HINT: Mark the Right-Hand and Left-Hand rack ends.

NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

c. Remove the washer from the rack end.
d. Employ the same manner described above to the other side.





6. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the lock nut.
SST 09922-10010

NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

7. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING AND RACK GUIDE SUB-ASSEMBLY
a. Using a hexagon wrench, remove the rack guide spring cap.
b. Remove the rack guide spring and rack guide sub-assembly.





8. REMOVE RACK HOUSING CAP
Using SST, remove the rack housing cap.
SST 09816-30010





9. REMOVE SELF-SOCKING NUT
Using SST to stop the control valve shaft rotating, remove the nut.
SST 09616-00011
10. REMOVE DUST COVER





11. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place matchmarks on the control valve housing and rack housing.
b. Remove the 2 bolts and control valve housing with control valve assembly.
c. Remove the gasket from the rack housing.





12. REMOVE CONTROL VALVE ASSEMBLY
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
b. Press out the valve assembly with the oil seal.

NOTICE:
^ Place a shop rag between the valve housing and the blocks.
^ Be careful not to drop the valve assembly.
^ Be careful not to damage the oil seal lip.

13. REMOVE OIL SEAL
Remove the oil seal from the control valve assembly.





14. REMOVE CYLINDER END STOPPER
a. Using SST, turn the stopper clockwise until the wire end is visible through the service hole.
SST 09631-16010
b. Using SST, turn the stopper counterclockwise, and remove the wire.
SST 09631-16010





15. REMOVE STEERING RACK AND BUSHING
a. Using SST, press out the steering rack with the bushing

NOTICE: Take care not to drop the rack.

SST 09950-70010 (09951-07200)
b. Remove the bushing from the rack.
c. Remove the O-ring from the bushing.





16. REMOVE OIL SEAL
Using SST, press out the oil seal.
SST 09950-60010 (09951-00360), 09950-70010 (09951-07360)

INSPECTION
INSPECT STEERING RACK





a. Using a dial indicator, check the rack for runout, teeth wear and damage.
Maximum runout: 0.03 mm (0.0118 inch)
b. Check the back surface for wear and damage.

REPLACEMENT

NOTICE: When using a vise, do not overtighten it.

1. IF NECESSARY, REPLACE OIL SEAL AND BEARING





a. Using Special Service Tool (SST), press out the oil seal and bearing from the control valve housing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07150)
b. Coat a new oil seal lip with power steering fluid.





c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Make sure to install the oil seal facing in the correct direction.

d. Coat a new bearing with molybdenum disulfide lithium base grease.





e. Using SST, press in the bearing.
SST 09950-60010 (09951-00340), 09950-70010 (09951-07150)
2. IF NECESSARY, REPLACE 2 BEARINGS





a. Using SST, press out the bearing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07150)





b. Using SST, press out the bearing from the rack housing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07150)
c. Coat a new bearing with molybdenum disulfide lithium base grease.





d. Using SST, press in the bearing.
SST 09950-60010 (09951-00310), 09950-70010 (09951-07150)
e. Coat a new bearing with molybdenum disulfide lithium base grease.





f. Using SST, press in the bearing.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07150)
3. IF NECESSARY, REPLACE OIL SEAL





a. Using SST, remove the oil seal from the bushing.
SST 09527-20011, 09612-24014 (09613-22011)

NOTICE: Be careful not to damage the bushing.

b. Coat a new oil seal lip with power steering fluid.





c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00300, 09951-00460, 09952-06010)

NOTICE: Make sure to install the oil seal facing in the correct direction.

4. IF NECESSARY, REPLACE TEFLON RING AND 0-RING





a. Using a screwdriver, remove the teflon ring and O-ring from the steering rack.

NOTICE: Be careful not to damage the groove for the teflon ring.

b. Coat a new O-ring with power steering fluid and install it to steering rack.





c. Expand a new teflon ring with your fingers.

NOTICE: Be careful not to over-expand the teflon ring.





d. Coat the teflon ring with power steering fluid.
e. Install the teflon ring to the steering rack, and settle it down with your fingers.
5. IF NECESSARY, REPLACE TEFLON RINGS





a. Using a screwdriver, remove the 4 teflon rings from the control valve assembly.

NOTICE: Be careful not to damage the grooves for the teflon ring.

b. Expand 4 new teflon rings with your fingers.

NOTICE: Be careful not to overexpand the teflon ring.

c. Coat the teflon rings with power steering fluid.
d. Install the teflon rings to the control valve assembly, and settle them down with your fingers.





e. Carefully slide the tapered end of SST over the teflon rings until they fit to the control valve assembly.
SST 09631-20081

NOTICE: Be careful not to damage the teflon rings.

REASSEMBLY

NOTICE: When using a vise, do not overtighten it.

1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE





2. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using Special Service Tool (SST), press in the oil seal.
SST 09950-60010 (09951-00330, 09951-00490, 09952-06010), 09950-70010 (09951-07360)

NOTICE:
^ Make sure to install the oil seal facing in the correct direction.
^ Take care that the oil seal does not get reversed as you install it.





3. INSTALL STEERING RACK
a. Install SST to the rack.
SST 09631-20051

HINT: If necessary, scrape the burrs off the rack teeth end and burnish.

b. Coat the SST with power steering fluid.
c. Install the steering rack into the rack housing.

NOTICE: Be careful not to damage the oil seal lip.

d. Remove the SST.
SST 09631-20051





4. INSTALL BUSHING
a. Coat a new O-ring with power steering fluid and install it to the bushing.
b. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
c. Install the bushing.

NOTICE:
^ Make sure to install the bushing facing in the correct direction.
^ Be careful not to damage the oil seal lip.





5. INSTALL CYLINDER END STOPPER
a. Align the installation hole for the wire of the stopper with the slot of the rack housing.
b. Install a new wire into the stopper.
c. Using SST, turn the stopper clockwise 450 ± 50°.
SST 09631-16010





6. AIR TIGHTNESS TEST
a. Install SST to the rack housing.
SST 09631-12071
b. Apply 53 kPa (400 mm Hg, 15.75 inch Hg) of vacuum for about 30 seconds.
c. Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil seals.





7. INSTALL CONTROL VALVE ASSEMBLY
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
b. Coat the teflon rings with power steering fluid.
c. Install the valve assembly into the valve housing.

NOTICE: Be careful not to damage the teflon rings and oil seal.





8. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST, press in the oil seal.
SST 09612-22011

NOTICE: Make sure to install the oil seal facing in the correct direction.

9. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place a new gasket on the rack housing.
b. Align the matchmarks on the control valve housing with control valve assembly and rack housing.
c. Install the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





10. INSTALL SELF-LOCKING NUT
Using SST to stop the control valve shaft rotating, install a new nut.
SST 09616-00011
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
11. INSTALL DUST COVER
12. INSTALL RACK HOUSING CAP





a. Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using SST, install the rack housing cap.
SST 09816-30010
Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.)





c. Using a punch and hammer, stake the 2 parts of the cap.
13. INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
a. Install the rack guide sub-assembly and rack guide spring.
b. Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Temporarily install the rack guide spring cap.
14. ADJUST TOTAL PRELOAD
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the Right-Hand and Left-Hand rack ends.
b. Using a hexagon wrench, install the rack guide spring cap.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





c. Using a hexagon wrench, return the rack guide spring cap 12°.





d. Using SST, turn the control valve shaft right and left 1 or 2 times.
SST 09616-00011
e. Using a hexagon wrench, loosen the rack guide spring cap until the rack guide spring is not functioning.





f. Using SST, torque wrench and hexagon wrench, tighten the rack guide spring cap until the preload is within specification.
SST 09616-00011
Preload (turning): 1.2 - 1.6 Nm (12 - 16 kgf-cm, 10.4 - 13.9 inch lbs.)





15. INSTALL RACK GUIDE SPRING CAP LOCK NUT
a. Apply sealant to 2 or 3 threads of the lock nut.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Temporarily install the lock nut.
c. Using a hexagon wrench to hold the rack guide spring cap, and using SST torque the lock nut.
SST 09922-10010
Torque: 44 Nm (450 kgf-cm, 32 ft. lbs.)

NOTICE: Use SST in the direction shown in the illustration.

SST 09922-10010

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

d. Recheck the total preload.
Preload (turning): 1.2 - 1.6 Nm (12 - 16 kgf-cm, 10.4 - 13.9 inch lbs.)
e. Remove the Right-Hand and Left-Hand rack ends.
16. INSTALL RIGHT-HAND AND LEFT-HAND CLAW WASHERS AND RACK ENDS





a. Install a new claw washer, and temporarily install the rack end.

HINT: Align the claws of the claw washer with the steering rack grooves.





b. Using a spanner to hold the steering rack steady, and using SST, torque the rack end.
SST 09922-10010
Torque: 76 Nm (770 kgf-cm, 56 ft. lbs.)

NOTICE: Use SST in the direction shown in the illustration.

SST 09922-10010

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).





c. Using a brass bar and hammer, stake the washer.

NOTICE: Avoid any impact on the rack.

d. Employ the same manner described above to the other side.
17. INSTALL RIGHT-HAND AND LEFT-HAND RACK BOOTS, CLAMPS AND CLIPS





a. Ensure that the steering rack hole is not clogged with grease.

HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.

b. Set a new clamp to the groove of the rack boot.





c. Install the boot.

NOTICE: Be careful not to damage or twist the boot.

d. Using SST, tighten the clamp as shown in the illustration.
SST 09521-24010
e. Install the clip to the rack boot.
f. Employ the same manner describer above to the other side.
18. INSTALL RIGHT-HAND AND LEFT-HAND TIE ROD ENDS AND LOCK NUTS
a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
b. After adjusting toe-in, torque the nut.
Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.)





19. INSTALL 2 TURN PRESSURE TUBES
a. Coat 4 new O-rings with power steering fluid and install them to the turn pressure tubes.
b. Using SST, install the 2 turn pressure tubes.
SST 09023-38400
Torque: 13 Nm (135 kgf-cm, 10 ft. lbs.)

HINT:
^ Use a torque wrench with a fulcrum length of 250 mm (9.84 inch).
^ This torque value is effective in case that SST is parallel to a torque wrench.