1.
Disconnect the cover fixing clip(A) on the universial joint indoor driver isde, loosen the noise covers(B).
Disconnect the cover fixing clip(A) on the universial joint indoor driver isde, loosen the noise covers(B).
Loosen the iniversial joint and the gear box mounting bolt and disconnect the universial joint from the gear box.
Keep the neutral-range to prevent the damage of the clock spring inner cable when you handlethe steering wheel.
Lift up the vehicle.
Remove the front tires (RH/LH).
After removing the split pin, disconnect the tie rod(A) from the knuckle(B) by using the special tool (09568-34000).
Drain the power steering fluid. (see page ST-11)
Remove the engine under cover(A).
Remove the front muffler assembly(A).
Disconnect the end tube of the pressure hose(A) and the end hose of the return hose(B) from the gear box.
Remove the bracket(A) holding the end tubes of the pressure tube and the return tube.
Remove the mounting clamp of power steering gear box, and also remove the clamp holding the pressure tube and the return tube.
Remove the mounting bolt(A) from the power steering gear box.
Pull the power steering gear box assembly(A) toward the right side of the vehicle.
When removing the gear box, pull it out carefully and slowly so as not to cause damage to the Bellows(B).
Push in the power steering gear box assembly(A) on the right side of the vehicle.
Install the dust cover mounting plate.
Connect the dust cover to its mounting plate with a new strap.
Connect the steering gear box assembly to the universal joint assembly(A) by using the bolt(B).
Installation is the reverse of removal.
After installation, air bleed the system.
(see page ST-11)
Remove the tie rod end(A) from the tie rod(B).
After mounting the tie rod end(A) in a vise, remove the dust cover(B) from the ball joint.
Remove the bellows band(A).
Remove the bellows clip(A).
Pull the bellows out toward the tie rod.
Check for rust on the rack when the bellows are replaced.
Remove the feed tube from the rack housing.
While moving the rack slowly, drain the fluid from the rack housing.
Unstake the tab washer(A) which fixes the tie rod(B) and rack(C) with a chisel.
Remove the tie rod(A) from the rack(B).
Remove the tie rod(A) from the rack(B), taking care not to twist the rack.
Remove the yoke plug locking nut(A), and then remove the yoke plug.
Remove the lock nut(A), yoke plug(B), rack support spring(C), rack support yoke(D) and bushing(E) from the gear box.
Remove the valve body housing(A) by loosening the two bolts(B).
Remove the rack bushing and the rack from the rack housing.
Remove the O-ring(A) from the rack bushing(B).
Remove the oil seal(A) from the rack bushing(B).
Remove the pinion vlave assembly(A) from the valve body housing(B) with a soft hammer(C).
Using the special tool, remove the oil seal and ball bearing from the valve body housing.
Remove the oil seal and O-ring from the rack housing.
Be careful not to damage the pinion valve cylinder inside of the rack housing.
Using the special tool(06573-21200, 09555-21000), remove the oil seal(A) from the rack housing.
Be careful not to damage the rack cylinder inside of the rack housing.
Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid : PSF-3
Install the oil seal(A) to the specified position in the rack housing.
Apply the specified fluid to the entire surface of the rack bushing oil seal .
Recommended fluid : PSF-3
Install the oil seal(A) in the rack bushing(B).
Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
Apply the specified grease to the rack teeth.
Recommended grease
Multipurpose grease SAE J310, NLGI No.2
Do not plug the vent hole(A) in the rack with grease.
Insert the rack into the rack housing and install the rack bushing and rack stopper.
Install the oil seal and the ball bearing in the valve body.
After appling the specified fluid and grease to the pinion valve assembly(A), install it in the rack housing assembly.
After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly(A) and O-ring in the gear box(B).
Install the tab washer and the tie rod and stake the tab washer(A) end at two points over the tie rod.
Align the tab washer pawls with the rack grooves.
Always use a new tab washer.
Install the bushing(A), rack support yoke(B), rack support spring(C), lock nut(E) and yoke plug(D) in the order shown in the illustration. Apply semi-drying sealantto to the threaded section of the yoke plu g before installation.
With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to 15 Nm (150 kg.cm, 11 lb.ft). Loosen the yoke plug approximately from 30° to60° and tighten the locking nut to the specified torque.
Tightening torque
50~70 Nm (500~700 kg.cm, 37~52 lb.ft)
Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
: Silicone grease
Install the new attaching band to the bellows.
When the bellows are installed, a new band must be used.
Install the bellows in position, taking care not to twist it.
Fill the dust cover inner side and lip with the specified grease, and fix the dust cover in position with the clip ring attached in the grooveof the tie rod end.
Recommended greas
A : POLY LUB GLY 801K or equivalent
B : SHOWA SUNLIGHT MB2 or equivalent
Dust cover inner side and lip : THREE BOND
Install the tie rods so that the length of the left and right tie rods equals the standard value.
Standard value
Tie rod free length : 112.2mm
Check for total pinion preload.
When mounting the gear box in a vise, let the installation section of it be fixed to the jaws. If other section is fixed the gear box may be damaged.
Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload.
Standard value
Total pinion preload :
0.6~1.3 Nm (6~13 kg.cm, 0.4~1.0 lb.ft)
Measure the pinion preload through the entire stroke of the rack.
If the measured value is out of specifications, first adjust the yoke plug, then recheck the total pinion preload.
If you adjust the yoke plug but do not obtain the total pinion preload, check or replace the yoke plug components
Rotate the tie rod severely ten times.
Measure the tie rod(A) swing resistance with a spring scale(B).
Standard value
Total rod swing resistance :
8~22 N (1.9~4.6 lb) [2~5 Nm (20~50 kg.cm, 17~43 lb.in)]
If the measured value exceeds the standard value, replace the tie rod as sembly.
Even if the measured value is below the standard value, the tie rod that swings smoothly without excessive play may be used. If the measured value is below 4.3 N (0.9 lb) [100 Ncm (8.7 lb.in.)], replace the tie rod.
Inspect the bellows for damage or deterioration.
Make sure the bellows are secured in the correct position.
If the bellows are defective, replace them with new ones.
When mounting the gear box in a vise, let the installation section of it be fixed to the jaws. If other section is fixed the gear box may be damaged.
Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload.
Standard value
Total pinion preload :
0.6~1.3 Nm (6~13 kg.cm, 0.4~1.0 lb.ft)
Measure the pinion preload through the entire stroke of the rack.
If the measured value is out of specifications, first adjust the yoke plug, then recheck the total pinion preload.
If you adjust the yoke plug but do not obtain the total pinion preload, check or replace the yoke plug components
Rotate the tie rod severely ten times.
Measure the tie rod(A) swing resistance with a spring scale(B).
Standard value
Total rod swing resistance :
8~22 N (1.9~4.6 lb) [2~5 Nm (20~50 kg.cm, 17~43 lb.in)]
If the measured value exceeds the standard value, replace the tie rod as sembly.
Even if the measured value is below the standard value, the tie rod that swings smoothly without excessive play may be used. If the measured value is below 4.3 N (0.9 lb) [100 Ncm (8.7 lb.in.)], replace the tie rod.
Inspect the bellows for damage or deterioration.
Make sure the bellows are secured in the correct position.
If the bellows are defective, replace them with new ones.
