Steering Rack Guide Preload Spring Install. Procedure

Precaution and Note

1. Place the front wheels facing straight ahead with the engine running.

2. Record the radio presets.

3. Turn the key to the OFF position and remove the keys from the ignition.

4. Disconnect the negative (-) battery terminal.

5. Remove the front wheels.

6. Remove the 6 bolts and the engine under cover assembly rear.

7. Remove the 4 bolts and the engine under cover sub-assembly No. 1.

8. Remove the 2 nuts and the front stabilizer link assembly LH.





NOTE:
If the front stabilizer link ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.





9. Remove the 2 nuts and the front stabilizer link assembly RH.

10. Remove the 2 bolts and the front stabilizer bracket No. 1 LH.

11. Remove the 2 bolts and the front stabilizer bracket No. 1 RH.

12. Remove the 2 front stabilizer bar bushings No. 1.

13. Remove the front stabilizer bar.

14. Separate the tie rod end sub-assembly LH.

A. Remove the cotter pin and nut.





B. Using the SST, separate the tie rod end from the steering knuckle arm.

SST P/N: 09628-62011

15. Separate the tie rod end sub-assembly RH.

A. Remove the cotter pin and nut.

B. Using the SST, separate the tie rod end from the steering knuckle arm.

SST P/N: 09628-62011

16. Remove the steering sliding yoke.

A. Mark matchmarks on the steering sliding yoke, steering intermediate shaft sub-assembly No. 2, and steering intermediate shaft assembly.





B. Remove the 2 bolts from the steering sliding yoke.

C. Slide the steering sliding yoke up and separate it from the steering intermediate shaft sub-assembly No. 2.

D. Pull down the steering sliding yoke from the steering intermediate shaft assembly to remove.

17. Remove the steering intermediate shaft No. 2.





A. Mark the matchmarks on the power steering gear assembly and steering intermediate shaft sub-assembly No. 2.

B. Remove the bolt and intermediate shaft sub-assembly No. 2 from the power steering gear assembly.

HINT:
When reinstalling the power steering gear assembly, be sure to align the match marks with the protrusion to install.

C. Align the notch with the protrusion of the gearbox to make match marks on the intermediate shaft No. 2.

18. Disconnect the pressure feed tube assembly.

A. Using the 17 mm Union nut wrench (or equivalent), loosen the flare nut and disconnect the pressure feed tube.





B. Remove the 2 bolts and separate the pressure feed tube assembly from the frame sub-assembly.

19. Disconnect the steering gear outlet return tube.





A. Remove the clip and disconnect the return hose.





B. Using the 17 mm Union nut wrench (or equivalent), remove the outlet return tube.





20. Remove the 2 bolts, 2 nuts, and power steering link assembly.

NOTE:
Be sure to only turn the bolt as the nut has a detent.

HINT:
After loosening the 2 bolts, raise the bolt from the frame. Slide the power steering gear assembly and the bolt as a unit to the position where the bolt can be pulled out.





21. Carefully secure the power steering gear assembly in a vise (if available, use SST P/N: 09612-00012-01).

22. Remove the rack guide.





A. Using the SST, remove the lock nut as shown in the illustration.

SST P/N: 09922-10010-01





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

C. Remove the spring and rack guide.

23. Install the rack guide spring.

A. Install the rack guide and new spring (P/N: 44215-35010).





B. Apply sealant to 2 or 3 threads of the rack guide spring cap.

Sealant: Three Bond 1344, Loctite 242, or equivalent

C. Using a hexagon wrench (24 mm), temporarily install the spring cap.

24. Adjust the total preload.

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

Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)





B. Turn the cap an additional 300 counterclockwise.

C. Using the SST, turn the control valve shaft right and left 1 or 2 times.

^ SST P/N: 09616-00010-02

D. Using a hexagon wrench (24 mm), loosen the cap until the rack guide spring has no tension.

E. Using the SST, a torque wrench, and a hexagon wrench (24 mm), tighten the cap until the preload is within specification.

SST 09616-00010-02

Preload (turning): 1.4 to 1.6 N.m (14.3 to 16.3 kgf.cm, 12.4 to 14.2 in.lbf)





NOTE:
When making the adjustment, be sure to turn the cap in the clockwise direction.

F. Apply sealant to 2 or 3 threads of the lock nut.

Sealant: Three Bond 1344, Loctite 242, or equivalent

G. Temporarily install the lock nut.





H. Using a hexagon wrench (24 mm), holding the rack guide from rotating, and using the SST, torque the nut.

^ SST 09922-10010-01

Torque: 69 N.m (700 kgf.cm, 51 ft.lbf) for use with SST





I. Recheck the total preload.

Preload (turning): 1.4 to 1.6 N.m (14.3 to 16.3 kgf.cm, 12.4 to 14.2 in.lbf)

25. Install the power steering link assembly into the vehicle with the 2 bolts and 2 nuts. Torque: 100 N.m (1,020 kgf.cm, 74 ft.lbf)

NOTE:
The nut has a detent, so never turn the nut. Be sure to turn the bolt.





HINT:
Insert the bolts and position it with the power steering gear assembly as a unit.
Then install the bolts on the frame.

26. Install the front stabilizer bar.

27. Install the 2 front stabilizer bar bushings No. 1.

NOTE:

^ Install the bushing to the inner side of the bushing stopper on the stabilizer bar.





^ Install the stabilizer bushing No. 1 as shown in the illustration.





28. Install the front LH bushing and bracket with 2 bolts.

Torque: 40 N.m (410 kgf.cm, 30 ft.lbf)

29. Install the front RH bushing and bracket with 2 bolts.

Torque: 40 N.m (410 kgf.cm, 30 ft.lbf)





30. Install the front stabilizer link assembly LH with the 2 nuts.

Torque: 70 N.m (710 kgf.cm, 52 ft.lbf)

NOTE:
If the front stabilizer link ball joint turns together with the nut, use a hexagon (6 mm) wrench to hold the stud.

31. Install the front stabilizer link assembly RH with the 2 nuts.

Torque: 70 N.m (710 kgf.cm, 52 ft.lbf)

32. Connect the steering gear outlet return tube.

A. Using the 17 mm Union nut wrench (or equivalent), connect the outlet return tube.

Torque: 44 N.m (440 kgf.cm, 32 ft.lbf)

HINT:

^ Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).





^ This torque wrench should be held as shown in the illustration.





B. Install the hose with the clip.

33. Connect the pressure feed tube assembly.





A. Install the pressure feed tube assembly to the frame sub-assembly with the 2 bolts.

Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)

B. Using the 17 mm Union nut wrench (or equivalent), tighten the flare nut and connect the pressure feed tube.

Torque: 44 N.m (440 kgf.cm, 32 ft.lbf)

NOTE:

^ Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).





^ This torque wrench should be held as shown in the illustration.





34. Install the steering intermediate shaft No. 2.

A. Align the matchmarks on the power steering gear assembly and steering intermediate shaft No. 2.

B. Install the steering intermediate shaft No. 2 to the power steering gear assembly with the bolt.

Torque: 36 N.m (370 kgf.cm, 27 ft.lbf)





35. Install the steering sliding yoke.

A. Install the steering sliding yoke to the steering column assembly and slide it upward.

B. Install the steering sliding yoke to the intermediate shaft No. 2 with the 2 bolts.

Torque: 36 N.m (370 kgf.cm, 27 ft.lbf)

36. Connect the tie rod end sub-assembly LH.

A. Connect the tie rod end to the steering knuckle arm.

B. Install the nut and cotter pin.

Torque: 91 N.m (928 kgf.cm, 67 ft.lbf)

37. Connect the tie rod end sub-assembly RH.

A. Connect the tie rod end to the steering knuckle arm.

B. Install the nut and cotter pin.

Torque: 91 N.m (928 kgf.cm, 67 ft.lbf)

38. Install the engine under cover sub-assembly No. 1 with the 4 bolts.

39. Install the engine under cover assembly rear with the 6 bolts.

40. Install the front wheel.

Torque: 112 N.m (1,142 kgf.cm, 83 ft.lbf)

41. Place the front wheels facing straight ahead.

42. Add power steering fluid.

43. Bleed the power steering fluid.

A. Check the fluid level.

B. Ensure that the front of the vehicle is slightly higher than the rear of the vehicle to aid in air bleeding of steering rack.

C. Turn the steering wheel. With the engine stopped, turn the wheel slowly from lock to lock several times.

D. Lower the vehicle.

E. Reconnect the negative (-) battery terminal.

F. Start the engine. Run the engine at idle for a few minutes.

G. Turn the steering wheel.

a. With the engine idling, turn the wheel to left or right full lock position and keep it there for 2 to 3 seconds. Then turn the wheel to the opposite full lock position and keep it there for 2 to 3 seconds.

b. Repeat step "a" several times.

H. Stop the engine.





I. Check for foaming or emulsification. If the system has to be bled twice because of foaming or emulsification, check for fluid leaks in the system.

J. Check the fluid level.

44. Check the power steering fluid leakage.

45. Inspect and adjust the wheel alignment. Inspect the vehicle alignment using the instructions provided on the Technical Information System (TIS): 2003 or 2004 model year GX 470 Repair Manual: Front Suspension: Front Wheel Alignment: Adjustment

46. Return to Diagnostic Procedure", step 4, to continue procedure.

NOTE:
When repair is complete, initialize the power windows according to the procedure in TSIB No. PD018-05, "Initialization of Power Window During PDS."