STEERING GEAR AND LINKAGE ASSEMBLY


id061300802100

Special service tool (SST)

49 B032 317
 
Bearing & oil seal remover
49 T028 301
 
Dust boot installer
49 JP02 001
 
Adjustable wrench
49 T025 001
 
Boot clamp crimpers

Replacement part

Boot band
 
Quantity: 2
 
Location of use: Boot
Mounting rubber
 
Quantity: 3
 
Location of use: Steering gear

Oil and chemical type

Grease
 
Type: Molywhite

Caution
•  If using a vise, secure the steering gear to the vise using a copper plate or cloth to prevent steering gear damage.

1.  Assemble in the order shown in the figure.

2.  Install the steering gear and linkage to the front crossmember component. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

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1
Steering gear
2
Mounting rubber
3
Tie rod
4
Boot
5
Boot band
6
Boot clamp
7
Locknut
8
Tie-rod end
9
Dust cover


Mounting Rubber Assembly Note

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

2.  Press the mounting rubber until the mounting rubber end (lower side) comes out completely from the gear housing using the SST and a press as shown in the figure.

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Note
•  Press the mounting rubber until the mounting rubber end (upper side) comes into the gear housing slightly.

3.  Reverse the gear housing and press the mounting rubber until the mounting rubber end (upper side) contacts the gear housing using the SST and a press.

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4.  Verify that both ends of the mounting rubber are correctly assembled to the gear housing without any gaps as shown in the figure.

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•  If there are any gaps, adjust the position again using the SST and a press.


Tie Rod Assembly Note

1.  Install the SST to the torque wrench as shown in the figure, set it on the tie rod, and then measure dimensions A and L shown in the figure.

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2.  Tighten the tie rod using the SST after calculating the tightening torque using the following formula.

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Tightening torque
100—110 N·m {10.2—11.2 kgf·m, 74—81 ft·lbf}
Formula
T×(L/A)
T: Tightening torque
L: Torque wrench effective length
A: Dimension A measured in Step 1


Boot Band Assembly Note

1.  Assemble the boot band to the boot.

2.  Crimp the boot band using the SST.

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3.  Verify that crimp A of the boot band is within the standard.

Standard
1.5—2.5 mm {0.060—0.098 in}
•  If crimp A exceeds the standard, decrease the opening width of the SST and crimp the boot band again.
•  If width A of the crimp is less than the standard, increase the opening width of the SST and crimp a new boot band.

4.  Rotate the boot by hand and verify that the boot is securely installed by the boot band.


Tie-rod End Assembly Note

1.  Align the marks that were made before removing the tie-rod end, and assemble the tie-rod end to the tie rod.

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Note
•  When newly replacing a tie-rod end, place alignment marks on the new part in the same position as the removed tie-rod end.
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2.  Verify that dimension A shown in the figure is within the standard.

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Standard
8.9—21.9 mm {0.36—0.86 in}
•  If not within the standard, make adjustments so that dimension A is within the standard.