STEERING GEAR DISASSEMBLY


  1. FIX RACK & PINION POWER STEERING GEAR ASSEMBLY


    1. Using a union nut wrench, remove the 2 turn pressure tubes.

    2. A01KHBME01
      Text in Illustration
      *1 Vinyl Tape

      Using the SST, fix the gear assembly, between aluminum plates in a vise, as shown in the illustration.

      SST
      09612-00012

  2. REMOVE TIE ROD END SUB-ASSEMBLY LH


    1. Place matchmarks on the tie rod end, lock nut and rack end.

    2. Loosen the lock nut, remove the tie rod end and lock nut.

  3. REMOVE TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Remove the RH side by the same procedures with the LH side.

  4. REMOVE STEERING RACK BOOT NO.1 CLAMP


    1. Using pliers and a screwdriver, loosen the clamp.

    2. Remove the clip and boot.

      Note

      Be careful not to damage the boot.

      Tech Tips

      Mark the RH and LH boots.

  5. REMOVE STEERING RACK BOOT NO.2 CLAMP

    Tech Tips

    Remove the No.2 side by the same procedures with the No.1 side.

  6. REMOVE STEERING RACK BOOT NO.2

  7. REMOVE STEERING RACK BOOT NO.1

  8. REMOVE STEERING RACK END SUB-ASSEMBLY

    A01KESH

    1. Using a screwdriver and a hammer, stake back the washer.

      Note

      Avoid any impact to the steering rack.

    2. A01KFPEE01

      Using a spanner to hold the steering rack steady, and using SST, remove the rack end.

      SST
      09922-10010

      Note

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

    3. Remove the washer.

    4. Employ the same manner described above to the other side.

      Tech Tips

      Mark the RH and LH rack ends.

  9. REMOVE RACK GUIDE

    A01KI5AE01

    1. Using SST, remove the lock nut.

      SST
      09922-10010

      Note

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

    2. A01KFB3E01
      Text in Illustration
      *1 Hexagon Wrench

      Using a hexagon wrench (24 mm), remove the rack guide spring cap.

    3. Remove the spring and rock guide.

  10. REMOVE POWER STEERING CONTROL VALVE


    1. Remove the 2 bolts.

    2. Pull out the control valve assembly with the control valve housing.

    3. Remove the O-ring.

    4. Carefully mount the control valve assembly in a soft jaw vise.

    5. A01KERQE01
      Text in Illustration
      *1 Vinyl Tape

      Using SST, remove the bearing guide nut.

      SST
      09631-20060

      Note

      Be careful not to damage the oil seal lip.

    6. Remove the O-ring.

    7. Remove the dust cover.

    8. A01KHHWE01

      Using SST and a hammer, drive out the oil seal from the bearing guide nut.

      SST
      09950-60010   ( 09951-00300 )
      09950-70010   ( 09951-07100 )
    9. A01KGZ8E01
      Text in Illustration
      *1 Vinyl Tape

      Wind vinyl tape to the control valve shaft.

    10. Using a plastic hammer, tap out the valve assembly with the bearing guide nut from the control valve housing.

      Note

      Be careful not to damage the oil seal lip.

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

      Note

      Be careful not to damage the grooves for the ring.

    12. A01KGKJE01
      Text in Illustration
      *1 Screw Extractor

      Using a screw extractor, remove the union seat from the control valve housing.

  11. REMOVE POWER STEERING CONTROL VALVE UPPER OIL SEAL

    A01KESGE01

    1. Using SST, press out the bearing and oil seal from the control valve housing.

      SST
      09950-60010   ( 09951-00250 )
      09950-70010   ( 09951-07150 )

  12. REMOVE CYLINDER END STOPPER

    A01KGJ2E01

    1. Using SST, remove the stopper.

      SST
      09631-36010

    2. Remove the O-ring from the stopper.

  13. REMOVE POWER STEERING RACK

    A01KFB9E01

    1. Using SST, press out the steering rack and oil seal.

      SST
      09612-24014   ( 09612-10061 )

      Note

      Take care not to drop the rack.

    2. Remove the oil seal from the rack.

  14. REMOVE POWER STEERING CYLINDER TUBE OIL SEAL

    A01KHJSE01

    1. Using SST, press out the oil seal and spacer.

      SST
      09950-60010   ( 09951-00310, 09951-00300, 09952-06010 )
      09950-70010   ( 09951-07360 )

  15. INSPECT POWER STEERING RACK

    A01KHHOE01
    Text in Illustration
    *1 Dial Indication

    1. Using a dial indicator, check the rack for runout and for teeth wear and damage.

      Maximum runout
      0.15 mm (0.006 in.)

    2. Check the back surface for wear and damage.

  16. INSPECT TIE ROD END SUB-ASSEMBLY LH

    A01KIFI

    1. Flip the ball joint stud back and forth 5 times as shown in the figure, before installing the nut.

    2. Using a torque wrench, turn the nut continuously at a rate of 2 - 4 seconds per 1 turn and take the torque reading on the 5th turn.

      Torque(Turning)
      0.29 - 2.45 N*m (2.9 - 24.9 kgf*cm, 2.57 - 21.7 in.*lbf)

  17. INSPECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Inspect the RH side by the same procedures with the LH side.

  18. REMOVE POWER PISTON OIL SEAL


    1. Using a screwdriver, remove the teflon ring and oil seal from the steering rack.

      Note

      Be careful not to damage the groove for the ring.