1. |
Detach the power steering pressure hose
mounting clamp and the return tube mounting
clamp. |
2. |
Drain the power steering
fluid. |
3. |
Disconnect the pressure tube and the return
tube fittings from the gear box. |
4. |
Disconnect the shaft assembly from the gear
box inside the passenger compartment.

|
5. |
Remove the strap and push out the dust cover
and remove the dust cover mounting
plate. |
7. |
Remove the front tires
(RH/LH). |
8. |
After removing the split pin, disconnect the
tie rod from the knuckle by using the special tool
(09568-31000).

|
9. |
Remove the stabilizer bar (RH side) mounting
bracket and link nut.

|
10. |
After removing the rear roll stopper bracket
mounting bolt from the sub frame, remove the rear roll
stopper.

|
11. |
After loosing the sub frame mounting bolts a
little so as to be the sub frame assembly hung down
slightly.

|
12. |
Remove the power steering gear box mounting
bolts, pressure tube and the return tube clamp.

|
13. |
Pull the power steering gear box assembly
toward the right side of the vehicle.
When removing the gear box, pull it out
carefully and slowly to avoid
damaging. |

|
1. |
Push in the power steering gear box assembly
in the right side of the vehicle.

|
2. |
Install the dust cover mounting
plate. |
3. |
Connect the dust cover to its mounting plate
with a new strap. |
4. |
Connect the steering gear box assembly to the
steering column and shaft assembly.

|
5. |
Installation is the reverse of
removal. |
6. |
After installation, bleed the
system. |
1. |
Remove the tie rod end from the tie
rod.

|
2. |
After mounting the tie rod end in a vise,
remove the dust cover from the ball joint.

|
3. |
Remove the bellows band.

|
4. |
Remove the bellows clip.

|
5. |
Pull the bellows out toward the tie
rod.
Check for rust on the rack when the
bellows are
replaced. | |
6. |
Remove the feed tube from the rack
housing. |
7. |
While moving the rack slowly, drain the fluid
from the rack housing. |
8. |
Unstake the tab washer which fixes the tie rod
and rack with a chisel.

|
9. |
Remove the tie rod from the rack.
Remove the tie rod from the rack, taking
care not to twist the rack. |

|
10. |
Remove the yoke plug locking nut.

|
11. |
Remove the yoke plug with a 14mm
socket.

|
12. |
Remove the lock nut, yoke plug, rack support
spring, rack support yoke and bushing from the gear
box.

|
13. |
Remove the valve body housing by loosening the
two bolts.

|
14. |
Turn the rack stopper clockwise until the end
of the circlip comes out of the slot in the rack
housing.

|
15. |
When the end of the circlip comes out of the
notched hole of the housing rack cylinder, turn the rack stopper
counterclockwise and remove thecirclip.
Be careful not to damage the
rack. |

|
16. |
Remove the rack stopper, rack bushing and rack
from the rack housing. |
17. |
Remove the O-ring from the rack
bushing.

|
18. |
Remove the oil seal from the rack
bushing.

|
19. |
Remove the valve body from the valve body
housing with a soft hammer.

|
20. |
Using the special tool, remove the oil seal
and ball bearing from the valve body
housing. |
21. |
Remove the oil seal and O-ring from the rack
housing.
Be careful not to damage the pinion
valve cylinder bore of the rack
housing. | |
22. |
Using the special tool, remove the oil seal
from the rack housing.
Be careful not to damage the rack
cylinder bore of the rack
housing. |

|
INSPECTION AND ADJUSTMENT BEFORE
DISASSEMBLY |
When mounting the gear box in a vise, let the
installation section of it be fixed to the jaws. If other section is
fixed, the gear box may be damaged. |

TOTAL PINION PRELOAD
1. |
Rotate the pinion gear for approximately 4 to
6 seconds for one rotation to measure the total pinion
preload.
Standard
value
Total pinion preload :
0.6~1.3 Nm (6~13 kg•cm, 0.4~1.0
lb•ft)
|
Measure the pinion preload through the
entire stroke of the rack. |

|
2. |
If the measured value is out of
specifications, first adjust the yoke plug, then recheck the total
pinion preload. |
3. |
If not obtain the total pinion preload after
adjusting the yoke plug check or replace the yoke plug
components. |
TIE ROD SWING RESISTANCE
1. |
Rotate the tie rod severely ten
times. |
2. |
Measure the tie rod swing resistance with a
spring scale.
Standard
value
Total rod swing resistance
:
2~5 Nm (20~50 kg•cm, 1.4~3.6
lb•ft)
|

|
3. |
If the measured value exceeds the standard
value, replace the tie rod assembly.
Even if the measured value is below the
standard value, the tie rod that swings smoothly without
excessive play may be used. If the measuredvalue is below 0.44
kg•cm, replace the tie
rod. | |
BELLOWS INSPECTION
1. |
Inspect the bellows for damage or
deterioration. |
2. |
Make sure the bellows are secured in the
correct position. |
3. |
If the bellows are defective, replace them
with new ones. |
1. |
Apply the specified fluid to the entire
surface of the rack oil seal.
Recommended fluid :
PSF-3
| |
2. |
Install the oil seal to the specified position
in the rack housing.

|
3. |
Apply the specified fluid to the entire
surface of the rack bushing oil seal.
Recommended fluid :
PSF-3
| |
4. |
Install the oil seal in the rack
bushing.

|
5. |
Apply the specified fluid to the entire
surface of the O-ring and install it in the rack
bushing. |
6. |
Apply the specified grease to the rack
teeth.
Recommended
grease
Multipurpose grease SAE J310a, NLGI #2
EP
|
Do not plug the vent hole in the rack
with grease. |

|
7. |
Insert the rack into the rack housing and
install the rack bushing and rack stopper.

|
8. |
Push in the rack stopper until the circlip
groove of the rack stopper is aligned with the notched hole of the
rack housing. Install the circlip while turning the rack
stopper.
The circlip end should not be visible
through the notched hole of the rack
housing. |

|
9. |
Using a special tool, install the oil seal and
the ball bearing in the valve body housing.

|
10. |
After applying the specified fluid and grease
to the pinion valve assembly, install it in the rack housing
assembly.

|
11. |
After applying the specified fluid to the oil
seal, install it in the rack housing, and fix the valve body
assembly and O-ring in the gear box.

|
12. |
Install the tab washer and the tie rod and
stake the tab washer end at two points over the tie
rod.

|
13. |
Install the bushing, rack support yoke, rack
support spring and yoke plug in the order shown in the illustration.
Apply semi-drying sealantto the threaded section of the yoke plug
before installation.

|
14. |
With the rack placed in the center position,
attach the yoke plug to the rack housing. Tighten the yoke plug to
12 Nm (120 kg•cm, 8.9 lb•ft), with a 14mm socket. Loosen the yoke
plug approximately from 30° to 60°and tighten the yoke nut to the
specified torque.
Tightening
torque
50~70 Nm (500~700 kg•cm, 37~52
lb•ft)
|

|
15. |
Tighten the feed tube to the specified torque
and install the mounting rubber using
adhesive. |
16. |
Apply the specified grease to the bellows
mounting position (fitting groove) of the tie rod.

|
17. |
Install the new attaching band to the
bellows.
When the bellows are installed, a new
band must be
used. | |
18. |
Install the bellows in position, taking care
not to twist it. |
19. |
Fill the dust cover inner side and lip with
the specified grease, and fix the dust cover in position with the
clip ring attached in the grooveof the tie rod end.
Recommended
grease
A : POLY LUB GLY 801K or
equivalent
B : SHOWA SUNLIGHT MB2 or
equivalent
Dust cover inner side and lip : THREE
BOND
|

|
20. |
Install the tie rods so that the length of the
left and right tie rods equals the standard value.
Standard
value
Tie rod free length :
204.5mm
|

|
21. |
Check for total pinion
preload. |
INSPECTION AND ADJUSTMENT BEFORE
DISASSEMBLY |
When mounting the gear box in a vise, let the
installation section of it be fixed to the jaws. If other section is
fixed, the gear box may be damaged. |

TOTAL PINION PRELOAD
1. |
Rotate the pinion gear for approximately 4 to
6 seconds for one rotation to measure the total pinion
preload.
Standard
value
Total pinion preload :
0.6~1.3 Nm (6~13 kg•cm, 0.4~1.0
lb•ft)
|
Measure the pinion preload through the
entire stroke of the rack. |

|
2. |
If the measured value is out of
specifications, first adjust the yoke plug, then recheck the total
pinion preload. |
3. |
If not obtain the total pinion preload after
adjusting the yoke plug check or replace the yoke plug
components. |
TIE ROD SWING RESISTANCE
1. |
Rotate the tie rod severely ten
times. |
2. |
Measure the tie rod swing resistance with a
spring scale.
Standard
value
Total rod swing resistance
:
2~5 Nm (20~50 kg•cm, 1.4~3.6
lb•ft)
|

|
3. |
If the measured value exceeds the standard
value, replace the tie rod assembly.
Even if the measured value is below the
standard value, the tie rod that swings smoothly without
excessive play may be used. If the measuredvalue is below 0.44
kg•cm, replace the tie
rod. | |
BELLOWS INSPECTION
1. |
Inspect the bellows for damage or
deterioration. |
2. |
Make sure the bellows are secured in the
correct position. |
3. |
If the bellows are defective, replace them
with new
ones. | |