Steering Gear: Service and Repair

POWER STEERING GEAR AND LINKAGE





Components

Removal and Installation





CAUTION:
^ The rotation of the spiral cable (SRS "Air bag" component part) is limited. If the steering gear must be removed, set the front wheels in the straight-ahead direction. Do not rotate the steering column while the steering gear is removed.
^ Remove the steering wheel before removing the steering lower joint to avoid damaging the SRS spiral cable.





1. Detach tie-rod outer sockets.
2. Disconnect the power steering lines.
3. Disconnect the steering gear lower joint.
4. Position the bracket for the hoses and harness aside.
5. Remove the return line fitting.





6. Remove the steering gear mounting bolts.
7. Remove the steering gear through the passenger side.





8. Installation is the reverse order of removal.
^ Install power steering line connector.





^ Observe specified tightening torque when tightening high-pressure and low-pressure line connectors. Excessive tightening will damage threads of connector or O-ring.
Connector tightening torque
1 Low-pressure side: 28 - 39 Nm (2.8 - 4.0 kg-m, 21 - 28 ft. lbs.)
2 High-pressure: 15 - 25 Nm (1.5 - 2.5 kg-m, side 11 -18 ft. lbs.)
^ The O-ring in low-pressure pipe connector is larger than that in high-pressure connector. Take care to install the proper O-ring.





^ Initially, tighten nut on tie-rod outer socket and knuckle arm to 29 to 39 Nm (3 to 4 kg-m, 22 to 28 ft. lbs.). Then tighten further to align nut groove with first pin hole so that cotter pin can be installed.

CAUTION: Tightening torque must not exceed 49 Nm (5 kg-m, 36 ft. lbs.).





^ Before removing lower joint from gear, set gear in neutral (wheels in straight-ahead position). After removing lower joint, put matching mark on pinion shaft and pinion housing to record neutral position.
^ To install, set left and right dust boots to equal deflection. Attach lower joint by aligning matching marks of pinion shaft and pinion housing.





^ Tighten gear housing mounting bracket bolts and nut in the order shown.

Disassembly





1. Prior to disassembling, measure pinion rotating torque.
Within ±100° from the neutral position
Average rotating torque: 0.6 - 2.0 Nm (7 - 20 kg-cm, 6 - 17 inch lbs.)
Maximum torque deviation: 0.5 Nm (7 kg-cm, 5.8 inch lbs.)
Except for above measuring range
Maximum rotating torque: 1.9 Nm (19 kg-cm, 17 inch lbs.)
Maximum torque deviation: 0.65 Nm (7 kg-cm, 6 inch lbs.)
^ If pinion rotating torque is not within the specifications, replace steering gear assembly.
^ Before measuring, disconnect gear housing tube and drain fluid.
^ Use soft jaws when holding steering gear housing. Handle gear housing carefully, as it is made of aluminum. Do not grip cylinder in a vise.

2. Remove tie-rod outer sockets and boots.
3. Remove tie-rod inner sockets.

Inspection
Thoroughly clean all parts in cleaning solvent or Genuine DEXRON(tm) III or equivalent. Blow dry with compressed air, if available.

BOOT
^ Check condition of boot. If cracked excessively, replace it.
^ Check boots for accumulation of power steering fluid.

TIE-ROD OUTER AND INNER SOCKETS





^ Check outer and inner ball joints for swinging force "A" and axial end play "C".
^ Check outer ball joint for rotating torque "B".
^ Check condition of dust cover. If excessively cracked, replace outer tie-rod.

Assembly





1. Install tie-rod inner sockets, dust boots and outer sockets.
2. Tighten outer socket lock nut.





3. Measure rack stroke.





4. Before installing boot, coat the contact surfaces between boot and tie-rod with grease.





5. Install boot clamps.
^ Install large boot clamp using suitable tool and crimp securely.
^ Install small boot clamp as shown.