Disassembly and Assembly

Power Steering Gear (2 Of 2):

Power Steering Gear (1 Of 2):

DISASSEMBLY

NOTICE: When using a vise, do not over tighten it.





1. Secure PS gear assembly in vise. Secure the gear assembly on SST and clamp SST 09630-00014 (09631 -00142) in a vise.
2. Remove adjusting screw lock nut and seal washer.
3. Remove side cover.
a. Remove the 4 bolts.





b. Turn the cross shaft adjusting screw clockwise until the cover comes off.
c. Remove the O-ring from the cover.





4. Remove cross shaft. Using a plastic hammer, tap on the cross shaft end and pull out the shaft.





5. Remove power piston plunger guide nut, compression spring, power piston plunger and power piston plunger guide.
a. Using a 10 mm hexagon wrench, remove the plunger guide nut.
b. Remove the O-ring from the plunger guide nut.

6. Remove worm gear valve body assembly.
a. Remove the 4 bolts.





b. Using SST 09616-00010, turn the valve body shaft clockwise with holding the worm gear by your finger so it cannot move.





c. Pull out the valve body assembly.

NOTICE: Ensure that the worm gear does not come off the worm shaft.

d. Remove the 2 O-rings from the gear housing.




ASSEMBLY

NOTICE: When using a vise, do not over tighten it.

1. Coat with power steering fluid or molybdenum disulfide lithium ease grease.
2. Install worm gear valve body assembly.
a. Coat 2 new O-rings with power steering fluid and install them to the gear housing.





b. Secure the gear housing on SST 09630-00014 (09631-00142) and clamp SST in vise.





c. Install the valve body assembly while supporting the worm gear with your fingers so that it does not rotate.
d. Torque the 4 bolts.

Torque: 61 Nm (45 ft. lbs.)

NOTICE: Be careful not to damage the Teflon ring.





e. Using SST 09616-00010 and a torque wrench, check the valve body assembly rotating torque.

Rotating torque: 0.3 - 0.5 Nm (2.6 - 4.8 inch lbs.)

HINT: Hold the worm gear to prevent it from turning. If rotating torque is not correct, replace the worm gear valve body assembly.

3. Install power piston plunger guide, power piston plunger, compression spring and power piston plunger guide nut.
a. Coat a new O-ring with power steering fluid.





b. Install the O-ring to the plunger guide nut and install the plunger guide nut with a 10 mm hexagon wrench.

Torque: 20 Nm (15 ft. lbs.)

4. Determine center position.
a. Using SST 09616-0010, turn the worm gear valve body shaft so full lock in both directions and determine the exact center.





b. Place matchmarks on the worm gear valve body shaft and worm gear valve body housing to show neutral position.

5. Install cross shaft and side cover.
a. Coat a new O-ring with power steering fluid and install it to the side cover.
b. Assemble the cross shaft to the side cover.

HINT: Fully loosen the cross shaft adjusting screw.





c. Install and push the cross shaft into the gear housing so that the center teeth mesh together.
d. Torque the 4 bolts in a diagonal pattern.

Torque: 61 Nm (45 ft. lbs.)





6. Adjust total preload.
a. Install SST 09616-00010 with a torque wrench on the worm gear valve body shaft.
b. Turn the cross shaft adjusting screw until the preload is within specification.

Preload (Turning): 0.74 - 1 0.8 Nm (6.5 - 9.6 inch lbs.)

7. Install new seal washer.





8. Install adjusting screw lock nut. Torque the lock nut while holding the cross shaft adjusting screw.

Torque: 46 Nm (34 ft. lbs.)





9. Check total preload. Using SST 09616-00010 and a torque wrench, check total preload.

Total preload (Turning): 0.74 - 1.08 Nm (6.5 - 9.6 inch lbs.)