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STEERING GEAR AND LINKAGE ASSEMBLY

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  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.

1 | Gear housing
2 | Mounting rubber (See Mounting Rubber Assembly Note)
3 | Oil seal (See Oil Seal, Inner Guide Assembly Note)
4 | Inner guide (See Oil Seal, Inner Guide Assembly Note)
5 | O-ring
6 | Seal ring
7 | Steering rack
8 | U-gasket
9 | O-ring
10 | Holder (See Holder Assembly Note)
11 | Oil seal (See Oil Seal Assembly Note)
12 | Valve housing
13 | Upper bearing (See Upper Bearing Assembly Note)
14 | Pinion shaft
15 | Control valve
16 | Seal ring (See Seal Ring Assembly Note)
17 | Snap ring
18 | O-ring
19 | Bolt
20 | Support yoke
21 | Yoke spring
22 | Spring washer
23 | Adjusting cover (See Adjusting Cover Assembly Note)
24 | Locknut (adjusting cover)
25 | Washer
26 | Tie rod
27 | Boot
28 | Boot band
29 | Boot clamp
30 | Locknut
31 | Tie-rod end
32 | Oil pipe

## Mounting Rubber Assembly Note

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

2. Install the mounting rubber so that two notches of the mounting rubber are aligned to the steering rack.

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

4. Reverse the gear housing, then press the mounting rubber until the end of the mounting rubber comes out completely from the other side. At this time, align the end of the mounting rubber and the steel pipe.

## Oil Seal, Inner Guide Assembly Note

1. Install a new O-ring and seal ring to the piston part of the rack.

2. After installing the seal ring, seat it properly at the piston circumference.

3. Apply grease to a new oil seal and inner guide.

4. Install the oil seal to the SSTs.

5. Use the SST to move the oil seal to the edge of the steering rack piston.

6. Install the inner guide.

7. Put the steering rack into the gear box.

8. Press the oil seal and inner guide using the SSTs and a press until the force required suddenly increases.

## Holder Assembly Note

1. Apply grease to a new U-gasket and O-ring.

2. Install the U-gasket and O-ring to the holder.

3. Set the SST to the steering rack, and install the holder.

4. Stake the holder to the gear housing using a punch.

## Oil Seal Assembly Note

1. Apply grease to a new oil seal.

2. Press a new oil seal in using the SSTs and a press.

## Upper Bearing Assembly Note

1. Apply grease to a new bearing.

2. Press the bearing in using the SSTs.

## Seal Ring Assembly Note

1. Install a new seal ring to the valve part of the pinion shaft using the SST.

2. Using the SST, seat the seal ring properly.

3. Install the snap ring.

## Adjusting Cover Assembly Note

1. Set the rack to the center position.

2. Tighten the adjusting cover with 19.6 N·m {2 kgf·m, 14.5 ft·lbf} three times using the SST, and then turn back the adjusting cover to 44°.

3. Apply sealant to the threads of the locknut.

4. Attach the locknut.

5. Measure the rotational torque using the SST and a pull scale.

Rotational torque

  Center of rack ±90°: 0.78-1.18 N·m {8.0-12.1 kgf·cm, 7.0-10.4 in·lbf}
  [Pull scale reading: 7.8-11.8 N {0.8-1.2 kgf, 1.8-2.6 lbf}]

Except center of rack ±90°:

  1.67 N·m {17.0 kgf·cm, 14.7 in·lbf} or less
  [Pull scale reading: 16.7 N {1.7 kgf, 3.75 lbf} or less]

6. If not within the specification, repeat Steps 2-5.

7. Install the locknut using the SST (49 B032 320).

Tightening torque

  39-49 N·m {4.0-4.9 kgf·m, 29-36 ft·lbf}

## Hermetic Sealing inspection

1. Connect the SST to the power cylinder section of the gear housing.

2. Apply 53.3 kPa {400 mmHg, 15.7 inHg} vacuum with a vacuum pump and verify that it is held for at least 30 s.