STEERING GEAR AND LINKAGE ASSEMBLY

id061400801200

Caution

•  Place copper plates, rag, or similar material in a vise, when securing the mounting bracket portion of the steering gear.

1.  Assemble in the order indicated in the table.

L.H.D.

acxwzw00001808

1	Gear housing
2	Mounting rubber (See Mounting Rubber Assembly Note.)
3	Oil seal (See Oil Seal Assembly Note.)
4	Steering rack (See Steering Rack Assembly Note.)
5	O-ring
6	Rack bushing
7	Stopper (See Stopper Assembly Note.)
8	Clip
9	Oil seal (upper side) (See Oil Seal (upper side) Assembly Note .)
10	Bearing (upper side) (See Bearing (upper side) Assembly Note .)
11	Pinion shaft (See Pinion Shaft Assembly Note.)
12	Oil seal (lower side) (See Oil Seal (lower side) Assembly Note.)
13	Valve housing component
14	Locknut (pinion shaft side)
15	Housing cover (See Housing Cover Assembly Note.)
16	Dust cover (See Dust Cover Assembly Note .)
17	Clip
18	Support yoke
19	Yoke spring
20	Adjusting cover (See Adjusting Cover, Locknut (Adjusting Cover) Assembly Note.)
21	Locknut (adjusting cover) (See Adjusting Cover, Locknut (Adjusting Cover) Assembly Note.)
22	Tie rod (See Tie rod Assembly Note.)
23	Boot (See Boot Assembly Note.)
24	Boot band (See Boot Band (Crimp Type) Assembly Note.)
25	Boot clamp
26	Locknut
27	Tie-rod end
28	Oil pipe
29	Return pipe

R.H.D.

acxwzw00001809

1	Gear housing
2	Mounting rubber (See Mounting Rubber Assembly Note.)
3	Oil seal (See Oil Seal Assembly Note.)
4	Steering rack (See Steering Rack Assembly Note.)
5	O-ring
6	Rack bushing
7	Stopper (See Stopper Assembly Note.)
8	Clip
9	Oil seal (upper side) (See Oil Seal (upper side) Assembly Note .)
10	Bearing (upper side) (See Bearing (upper side) Assembly Note .)
11	Pinion shaft (See Pinion Shaft Assembly Note.)
12	Oil seal (lower side) (See Oil Seal (lower side) Assembly Note.)
13	Valve housing component
14	Locknut (pinion shaft side)
15	Housing cover (See Housing Cover Assembly Note.)
16	Dust cover (See Dust Cover Assembly Note .)
17	Clip
18	Support yoke
19	Yoke spring
20	Adjusting cover (See Adjusting Cover, Locknut (Adjusting Cover) Assembly Note.)
21	Locknut (adjusting cover) (See Adjusting Cover, Locknut (Adjusting Cover) Assembly Note.)
22	Tie rod (See Tie rod Assembly Note.)
23	Boot (See Boot Assembly Note.)
24	Boot band (See Boot Band (Crimp Type) Assembly Note.)
25	Boot clamp
26	Locknut
27	Tie-rod end
28	Oil pipe
29	Return pipe

Mounting Rubber Assembly Note

1.  Apply soapy water to the rubber part of the mounting rubber.

2.  Temporarily install the mounting rubber to the steering gear so that the mounting rubber are in the positions shown in the figure.

acxaaw00001238

Caution

•  If the mounting rubber is placed in the wrong position or assembled in the wrong direction, an installation malfunction will result when the vehicle is loaded. When assembling the mounting rubber, verify the position and directions.

acxaaw00000374

3.  Press the mounting rubber until the mounting rubber end comes out completely from the gear housing using the SSTs and a press.

acxaaw00000375

4.  Reverse the gear housing, then press the mounting rubber until the mounting rubber end comes out completely from the other side. At this time, make sure that the mounting rubber and steel pipe are aligned.

acxaaw00000376

Oil Seal Assembly Note

1.  Apply ATF to the lip of a new oil seal.

2.  Install the SST (49 N032 319A) to the gear housing with the raised part facing up as shown in the figure.

3.  Set the stopper into the gear housing to hold the SSTs as shown in the figure.

acxuuw00000998

4.  Install the oil seal using the SSTs (49 F032 303, 49 H032 326) and a press.

Steering Rack Assembly Note

1.  Apply multipurpose grease to the rack teeth.

2.  Install a plastic bag to the rack teeth and insert the steering rack in the gear housing.

acxuuw00000999

Stopper Assembly Note

1.  Using an appropriate pipe and a hammer, insert the rack stopper into the gear housing until the clip installation groove of the gear housing comes out.

acxuuw00001000

2.  Apply 53.3 kPa {400 mmHg, 15.8 inHg} vacuum with a vacuum pump and verify that it is held for 30 s.

acxuuw00001001

•  If the vacuum is not held, replace the oil seal.

Oil Seal (upper side) Assembly Note

1.  Assemble the oil seal (upper side) using the SST.

acxuuw00001002

Bearing (upper side) Assembly Note

1.  Assemble the bearing (upper side) using the SST.

acxuuw00001003

Oil Seal (lower side) Assembly Note

1.  Assemble the oil seal (lower side) using the SST.

acxuuw00001007

Pinion Shaft Assembly Note

1.  Assemble the pinion shaft using a press.

acxuuw00001006

Housing Cover Assembly Note

1.  Apply silicone sealant to the threads of the housing cover.

2.  Assemble the housing cover.

Dust Cover Assembly Note

1.  Apply grease to the oil dust cover shown in the figure.

acxuuw00002261

Adjusting Cover, Locknut (Adjusting Cover) Assembly Note

1.  Install two nuts to the bolt across a flat 24 mm {0.94 in} and tighten them using a wrench.

acxaaw00000377

2.  Using the bolt/nut produced in Step 1, install the adjusting cover.

(1)  Tighten the adjusting cover with a tightening torque of 20.0—29.0 N·m {2.1—2.9 kgf·m, 14.8—21.3 ft·lbf}.

(2)  Using the SST, loosen the adjusting cover to 25—30°.

acxaaw00000378

3.  Apply sealant to the locknut.

4.  Combine the the SST with the torque wrench, then measure A and L as shown in the figure.

acxaaw00001669

•  A: Length from the center of the locknut to the grip.

•  L: Length of the torque wrench.

5.  Recalculate the torque by using torque formulas, then secure the adjusting cover with the bolt and nuts created in Step 1, and tighten the locknut using the SST.

acxaaw00001239

Caution

•  If a tool such as a torque wrench is installed to the SST (49 E032 308), install the tool so that it is perpendicular to the SST as shown in the figure. If the tool is not installed as instructed, the SST can separate from the locknut easily which could cause damage to the locknut while doing the work.

Note

•  Be sure that the adjusting cover will not turn together with the locknut.

acxaaw00000379

Torque formula

6.  Measure the pinion torque using the SST and pull scale.

acxaaw00000380

•  If not as specified, remove the locknut and adjust the adjusting cover.

Tie rod Assembly Note

1.  Lock the steering rack end against rotation with a suitable wrench and install the tie rod.

acxaaw00000494

2.  Lock the steering rack end against rotation with a suitable wrench and install the other side tie rod.

acxaaw00000495

Boot Assembly Note

1.  Apply silicone grease to the rubber lip groove.

2.  Assemble the boot.

Boot Band (Crimp Type) Assembly Note

1.  Assemble the boot band to the boot.

2.  Crimp the boot band using the SST.

acxwzw00001805

3.  Rotate the boot by hand and verify that it is securely installed to the boot band.