STEERING GEAR AND LINKAGE ASSEMBLY

id061400801200

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

1. Assemble in the order indicated in the table.

a6e0612w044

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 | Backup ring
9 | U-gasket
10 | O‐ring
11 | Holder (See Holder Assembly Note)
12 | Oil seal (See Oil Seal Assembly Note)
13 | Valve housing
14 | Upper bearing (See Upper Bearing Assembly Note)
15 | Pinion shaft
16 | Control valve
17 | Seal ring (See Seal Ring Assembly Note)
18 | Snap ring
19 | O-ring
20 | Bolt
21 | Support yoke
22 | Yoke spring
23 | Adjusting cover (See Adjusting Cover Assembly Note)
24 | Locknut (adjusting cover)
25 | Washer (See Washer and Tie Rod Assembly Note)
26 | Tie rod (See Washer and Tie Rod Assembly Note)
27 | Boot
28 | Boot band
29 | Boot clamp
30 | Locknut
31 | Tie‐rod end
32 | Oil pipe
33 | Return pipe

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 comes out completely from the gear housing using the SSTs and a press.

a6e0612w087

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

d6e614zw3017

Oil Seal, Inner Guide Assembly Note

1. Install a new O-ring and a new seal ring to the rack’s piston.

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.

a6e0612w048

5. Using the SST, place the oil seal and inner guide at the edge of the steering rack’s pinion, and remove the SST.

a6e0612w049

6. After installing the steering rack to the gear housing, press the oil seal and inner guide using the SSTs until the force required suddenly increases.

a6e0612w039

Holder Assembly Note

1. Apply grease to the U-gasket and O-ring.

2. Assemble the U-gasket, backup ring and O-ring into the holder.

3. Assemble the SST to the steering rack.

a6e0612w090

4. Stake the holder to the cylinder using a punch.

a6e6316w012

Oil Seal Assembly Note

1. Apply grease to a new oil seal.

2. Press in the new oil seal using the SSTs.

a6e0612w036

Upper Bearing Assembly Note

1. Apply grease to a new upper bearing.

2. Press in the upper bearing using the SSTs.

a6e0612w051

Seal Ring Assembly Note

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

2. After installing it, seat it properly using the SST.

a6e0612w052

3. Install the snap ring.

Adjusting Cover Assembly Note

1. Set the rack to the center position.

2. Tighten the adjusting cover to 4.9 N·m {50 kgf·cm, 36 in·lbf} three times, then return it 25° using the SST.

a6e0612w062

3. Apply sealant to the threads of the locknut.

4. Attach the locknut.

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

a6e0612w042

  Pinion shaft rotation torque

  Center of rack ±90°: 0.7—1.1 N·m {7.2—11.2 kgf·cm, 6.2—9.7 in·lbf}
  [Pull scale reading 7—11 N {0.8—1.1 kgf, 1.6—2.4 lbf}]

  Except center of rack ±90°: Less than 1.6 N·m {16.3 kgf·cm, 11.8 in·lbf}
  [Pull scale reading Less than 16.7 N {1.7 kgf, 3.8 lbf}]

6. If not as specified, repeat steps 2 through 5.

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

a6e0612w056

  Tightening torque

  40—49 N·m {4.1—4.9 kgf·m, 30—36 ft·lbf}

Hermetic sealing inspection

1. Connect the SSTs 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.

a6e0612w054

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

Washer and Tie Rod Assembly Note

1. Assemble the washer and tie rod to the steering rack and tighten the tie rod to the specified torque.

2. Crimp the areas where the washer and the steering rack notch overlap (2 locations) using a punch.

am6uuw00001870