Steering Gear: Service and Repair

POWER STEERING GEAR

Components:

REMOVAL

NOTICE: Remove the steering wheel assembly before the steering gear removal, because there is possibility of breaking of the spiral cable.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
a. Wait for 90 seconds after disconnecting the cable to prevent the airbag working.

2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3. REMOVE STEERING WHEEL PAD
4. REMOVE STEERING WHEEL ASSEMBLY
5. DISCONNECT TIE ROD END SUB-ASSEMBLY LH
6. DISCONNECT TIE ROD END SUB-ASSEMBLY RH
7. DISCONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY
8. DISCONNECT CLAMP PLATE
a. Remove the bolt and disconnect the clamp plate.

9. DISCONNECT PRESSURE FEED TUBE ASSEMBLY

10. DISCONNECT RETURN TUBE ASSEMBLY
a. Using SST, disconnect the tubes.
SST 09023-12701

11. REMOVE POWER STEERING GEAR ASSEMBLY
a. Remove the bolt, nut and stud bolt from the bracket.
b. Remove the 2 set bolts, nut, washer and PS gear assembly.

12. REMOVE BRACKET AND GROMMET

DISASSEMBLY

NOTICE: When using a vise, do not overtighten it.

1. REMOVE TURN PRESSURE TUBE ASSEMBLY
a. Using SST, remove the 2 turn pressure tubes.
SST 09023-38401
b. Remove the 4 O-rings from the tubes.

2. SECURE POWER STEERING GEAR ASSEMBLY IN VISE
a. Using SST, 2 bolts and nuts, secure the gear assembly in a vise, as shown in the illustration.
SST 09612-00012 Reference:
Bolt: 90105-10346
Nut: 90170-10198

HINT: Use 2 of the same type of SST

3. REMOVE TIE ROD END SUB-ASSEMBLY LH
a. Put matchmarks on the tie rod end, lock nut and rack end.
b. Loosen the lock nut, remove the tie rod end and lock nut.
c. Perform the same procedure on the other side.

4. REMOVE TIE ROD END SUB-ASSEMBLY RH
a. Put matchmarks on the tie rod end, lock nut and rack end.
b. Loosen the lock nut, remove the tie rod end and lock nut.
c. Perform the same procedure on the other side.

5. REMOVE CLIP, RACK BOOTS AND CLAMPS
a. Using a screwdriver, loosen the 2 clamps.
b. Remove the 2 clips and boots.

HINT: Mark the RH and LH boots.

NOTICE: Be careful not to damage the boot.

6. REMOVE STEERING RACK END

a. Using a screwdriver and hammer, unstake the washer.

NOTICE: Avoid any impact on the steering rack.

b. Using a spanner, hold the steering rack steadily, and using SST, remove the rack end.
SST 09922-10010

HINT: Mark the RH and LH rack ends.

NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

c. Remove the washer from the rack end.
d. Perform the same procedure on the other side.

7. REMOVE RACK GUIDE SPRING CAP LOCK NUT
a. Using SST, remove the lock nut.
SST 09922-10010

NOTICE: Use SST 09922-10010 in the direction shown in the illustration.

8. REMOVE RACK GUIDE SPRING CAP, RACK GUIDE SPRING AND RACK GUIDE SUB-ASSEMBLY
a. Using a hexagon wrench, remove the rack guide spring cap.
b. Remove the rack guide spring and rack guide subassembly.

9. REMOVE RACK HOUSING CAP
a. Using SST, remove the rack housing cap.
SST 09816-30010

10. REMOVE SELF-LOCKING NUT
a. Using SST, stop the control valve shaft rotation, and remove the nut.
SST 09616-00011

11. REMOVE DUST COVER

12. REMOVE CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Put matchmarks on the control valve housing and rack housing.
b. Remove the 2 bolts and control valve housing with control valve assembly attached.
c. Remove the gasket from the rack housing.

13. REMOVE CONTROL VALVE ASSEMBLY
a. To prevent oil seal lip damage, wind vinyl tape around the serrated part of the valve shaft.
b. Press out the valve assembly with the oil seal.

NOTICE:
^ Place a shop rag between the valve housing and the blocks.
^ Be careful not to drop the valve assembly.
^ Be careful not to damage the oil seal lip.

14. REMOVE OIL SEAL
a. Remove the oil seal from the control valve assembly.

15. REMOVE CYLINDER END STOPPER
a. Using SST, turn the stopper clockwise until the wire end can be seen through the service hole.
SST 09631-16010
b. Using SST, turn the stopper counterclockwise, and remove the wire.
SST 09631-16010

16. REMOVE STEERING RACK AND BUSHING
a. Using SST, press out the steering rack with the bushing.

NOTICE: Take care not to drop the rack.

SST 09950-70010 (09951-07200)
b. Remove the bushing from the rack.
c. Remove the O-ring from the bushing.

17. REMOVE OIL SEAL
a. Using SST, press out the oil seal.
SST 09950-60010 (09951-00360), 09950-70010 (09951-07360)

INSPECTION

1. INSPECT STEERING RACK
a. Using a dial indicator, check the rack for runout, teeth wear and damage.
Maximum runout: 0.09 mm (0.0035 inch)
b. Check the back surface for wear and damage.

REPLACEMENT

NOTICE: When using a vise, do not overtighten it.

1. REPLACE BEARING AND OIL SEAL

a. Using SST, press out the oil seal and bearing from the control valve housing.
SST 09950-60010 (09951-00250), 09950-70010 (09951-07150)

b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07150)

NOTICE: Make sure to install the oil seal in the correct direction.

d. Coat a new bearing with molybdenum disulfide lithium base grease.
e. Using SST, press in the bearing.
SST 09950-60010 (09951-00340), 09950-70010 (09951-07150)

2. REPLACE BEARING

a. Using SST, press out the bearing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07150)

b. Using SST, press out the bearing from the rack housing.
SST 09950-60010 (09951-00260), 09950-70010 (09951-07150)

c. Coat a new bearing with molybdenum disulfide lithium base grease.
d. Using SST, press in the bearing.
SST 09950-60010 (09951-00310), 09950-70010 (09951-07150)

e. Coat a new bearing with molybdenum disulfide lithium base grease.
f. Using SST, press in the bearing.
SST 09950-60010 (09951-00320), 09950-70010 (09951-07150)

3. INSPECT OIL SEAL

a. Using SST, remove the oil seal from the bushing.
SST 09527-20011, 09612-24014 (09613-22011)

NOTICE: Be careful not to damage the bushing.

b. Coat a new oil seal lip with power steering fluid.
c. Using SST, press in the oil seal.
SST 09950-60010 (09951-00300, 09951-00460, 09952-06010)

NOTICE: Make sure to install the oil seal in the correct direction.

4. REPLACE TEFLON RING AND O-RING

a. Using a screwdriver, remove the teflon ring and O-ring from the steering rack.

NOTICE: Be careful not to damage the groove for the teflon ring.

b. Coat a new O-ring with power steering fluid and install it on steering rack.

c. Expand a new teflon ring with your fingers.

NOTICE: Be careful not to over-expand the teflon ring.

d. Coat the teflon ring with power steering fluid.
e. Install the teflon ring on the steering rack, and settle it down with your fingers.

5. REPLACE TEFLON RINGS

a. Using a screwdriver, remove the 4 teflon rings from the control valve assembly.

NOTICE: Be careful not to damage the grooves for the teflon ring.

b. Expand 4 new teflon rings with your fingers.

NOTICE: Be careful not to expand the teflon ring excessively.

c. Coat the teflon rings with power steering fluid.
d. Install the teflon rings on the control valve assembly, and settle them down with your fingers.

e. Carefully slide the tapered end of SST over the teflon rings until they fit to the control valve assembly.
SST 09631-20081

NOTICE: Be careful not to damage the teflon rings.

REASSEMBLY

NOTICE: When using a vise, do not overtighten it.

1. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID OR MOLYBDENUM DISULFIDE LITHIUM BASE GREASE

2. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST, press in the oil seal.
SST 09950-60010 (09951-00330, 09951-00490, 09952-06010), 09950-70010 (09951-07360)

NOTICE:
^ Make sure to install the oil seal in the correct direction.
^ Take care that the oil seal does not get reversed as you install it.

3. INSTALL STEERING RACK
a. Install SST to the rack.
SST 09631-20051

HINT: If necessary, scrape the burrs off the rack teeth end and burnish.

b. Coat the SST with power steering fluid.
c. Install the steering rack into the rack housing.

NOTICE: Be careful not to damage the oil seal lip.

d. Remove the SST

SST 09631-20051

4. INSTALL BUSHING
a. Coat a new O-ring with power steering fluid and install it on the bushing.
b. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
c. Install the bushing.

NOTICE:
^ Make sure to install the bushing in the correct direction.
^ Be careful not to damage the oil seal lip.

5. INSTALL CYLINDER END STOPPER
a. Align the installation hole for the wire of the stopper with the slot of the rack housing.
b. Install a new wire into the stopper.
c. Using SST, turn the stopper clockwise 400° to 500°.
SST 09631-16010

6. AIR TIGHTNESS TEST
a. Install SST to the rack housing.
SST 09631-12071
b. Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for about 30 seconds.
c. Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the oil seals.

7. INSTALL CONTROL VALVE ASSEMBLY
a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
b. Coat the teflon rings with power steering fluid.
c. Install the valve assembly into the valve housing.

NOTICE: Be careful not to damage the teflon rings and oil seal.

8. INSTALL OIL SEAL
a. Coat a new oil seal lip with power steering fluid.
b. Using SST, press in the oil seal.
SST 09612-22011

NOTICE: Make sure to install the oil seal in the correct direction.

9. INSTALL CONTROL VALVE HOUSING WITH CONTROL VALVE ASSEMBLY
a. Place a new gasket on the rack housing.
b. Align the matchmarks on the control valve housing with the one on the rack housing.
c. Install the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)

10. INSTALL SELF-LOCKING NUT
a. Using SST, stop the control valve shaft rotation, install a new nut.
SST 09616-00011
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

11. INSTALL DUST COVER
12. INSTALL RACK HOUSING CAP

a. Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using SST, install the rack housing cap.
SST 09816-30010
Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.)

c. Using a punch and hammer, stake the 2 parts of the cap.

13. INSTALL RACK GUIDE SUB-ASSEMBLY, RACK GUIDE SPRING AND RACK GUIDE SPRING CAP
a. Install the rack guide sub-assembly and rack guide spring.
b. Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
c. Temporarily install the rack guide spring cap.

14. ADJUST TOTAL PRELOAD

a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.
b. Using a hexagon wrench, install the rack guide spring cap.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
c. Using a hexagon wrench, return the rack guide spring cap 120.

d. Using SST, turn the control valve shaft right and left 1 or 2 turns.
SST 09616-00011
e. Using a hexagon wrench, loosen the rack guide spring cap until the rack guide spring does not functioning.

f. Using SST, torque wrench and hexagon wrench, tighten the rack guide spring cap until the preload becomes within specification.
SST 09616-00011
Preload (turning): 1.2 to 1.6 Nm (12 to 16 kgf-cm, 10.4 to 13.9 inch lbs.)

15. INSTALL RACK GUIDE SPRING CAP LOCK NUT
a. Apply sealant to 2 or 3 threads of the lock nut.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Temporarily install the lock nut.
c. Using a hexagon wrench, hold the rack guide spring cap, and using SST, tighten the lock nut.
SST 09922-10010
Torque: 44 Nm (450 kgf-cm, 32 ft. lbs.)

NOTICE: Use SST in the direction shown in the illustration.

SST 09922-10010

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

d. Recheck the total preload.
Preload (turning): 1.2 to 1.6 Nm (12 to 16 kgf-cm, 10.4 to 13.9 inch lbs.)
e. Remove the RH and LH rack ends.

16. INSTALL CLAW WASHER AND RACK END

a. Install a new claw washer, and temporarily install the rack end.

HINT: Align the claws of the claw washer with the steering rack grooves.

b. Using a spanner, hold the steering rack steady, and using SST, tighten the rack end.
SST 09922-10010
Torque: 76 Nm (770 kgf-cm, 56 ft. lbs.)

NOTICE: Use SST in the direction shown in the illustration.

SST 09922-10010

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

c. Using a brass bar and hammer, stake the washer.

NOTICE: Avoid any impact to the rack.

d. Perform the same procedure on the other side.

17. INSTALL RACK BOOT, CLAMP AND CLIP

a. Ensure that the steering rack hole is not clogged with grease.

HINT: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.

b. Set a new clamp to the groove of the rack boot.

c. Install the boot.

NOTICE: Be careful not to damage or twist the boot.

d. Using SST, tighten the clamp as shown in the illustration.
SST 09521-24010
e. Install the clip to the rack boot.
f. Perform the same procedure on the other side.

18. INSTALL TIE ROD ENDS AND LOCK NUTS
a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
b. After adjusting toe-in, tighten the nut.
Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.)

19. INSTALL 2 TURN PRESSURE TUBES
a. Coat 4 new O-rings with power steering fluid and install them on the turn pressure tubes.
b. Using SST, install the 2 turn pressure tubes.
SST 09023-38401
Torque: 13 Nm (135 kgf-cm, 10 ft. lbs.)

HINT:
^ Use a torque wrench with a fulcrum length of 250 mm (9.84 inch).
^ This torque value is effective in case that SST is parallel to a torque wrench.

INSTALLATION

1. INSTALL GROMMET AND BRACKET
2. INSTALL POWER STEERING GEAR ASSEMBLY
a. Install the PS gear assembly with the gear assembly set bolt A.
Torque: 165 Nm (1,700 kgf-cm, 123 ft. lbs.)
b. Install the gear assembly set bolt B, washer and nut B.
Torque: 130 Nm (1,350 kgf-cm, 96 ft. lbs.)
c. Install the stud bolt C to the bracket.
Torque: 20 Nm (200 kgf-cm, 15 ft. lbs.)
d. Install the bolt D and nut D to the bracket.
Torque: 165 Nm (1,700 kgf-cm, 123 ft. lbs.)

3. CONNECT RETURN TUBE
a. Using SST, connect the tubes.
SST 09023-12701
Torque: 22 Nm (227 kgf-cm, 16 ft. lbs.)

HINT:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
^ This torque value is effective in case that SST is parallel to a torque wrench.

4. CONNECT PRESSURE FEED TUBE
a. Using SST, connect the tubes.
SST 09023-12701
Torque: 22 Nm (227 kgf-cm, 16 ft. lbs.)

HINT:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
^ This torque value is effective in case that SST is parallel to a torque wrench.

5. CONNECT CLAMP PLATE
a. Connect the clamp plate and install the bolt.
Torque: 29 Nm (290 kgf-cm, 21 ft. lbs.)

6. CONNECT NO. 2 INTERMEDIATE SHAFT ASSEMBLY
7. CONNECT TIE ROD END SUB-ASSEMBLY LH
8. CONNECT TIE ROD END SUB-ASSEMBLY RH
9. FACE FRONT WHEELS STRAIGHT AHEAD

HINT: Do it with the front of the vehicle jacked up.

10. CENTER SPIRAL CABLE
11. INSTALL STEERING WHEEL ASSEMBLY
a. Align the matchmark on the wheel with the one on the steering column main shaft.
b. Temporarily tighten the wheel set nut.
c. Connect the connector.

12. BLEED AIR FROM POWER STEERING SYSTEM
13. CHECK STEERING WHEEL CENTER POINT
14. TORQUE STEERING WHEEL SET NUT
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
15. INSTALL STEERING WHEEL PAD
16. CHECK FRONT WHEEL ALIGNMENT
17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
18. PERFORM YAW RATE AND DECELERATION SENSOR ZERO POINT CALIBRATION
19. PERFORM INITIALIZATION
a. Perform initialization.

HINT: Some systems need initialization when disconnecting the cable from the negative battery terminal.