STEERING SYSTEM SECTION ST CONTENTS STEERING ST-1 SYMPTOM DIAGNOSIS... 3 PRECAUTION... 7 PREPARATION... 9 ON-VEHICLE MAINTENANCE...

Transcription

1 RG ST RG SY TTS SYT GSS... 3 S, VRT RSSS (V) TRUSTG... 3 V Troubleshooting hart...3 RUT... 7 RUTS... 7 recaution for Supplemental Restraint System (SRS) "R G" and "ST T R-T- SR"...7 recaution ecessary for Steering Wheel Rotation after attery isconnect...7 Service otice or recautions for Steering System...7 RRT... 9 RRT... 9 Special Service Tools...9 ommercial Service Tool V T...11 WR RG U...11 nspection...11 RG W...13 nspection V RR...16 RG W...16 xploded View...16 Removal and nstallation...16 RG U...17 WTUT TR TR...17 WTUT TR TR : xploded View...17 WTUT TR TR : Removal and nstallation...17 WTUT TR TR : nspection...18 WT TR TR...19 WT TR TR : xploded View...20 WT TR TR : Removal and nstallation...20 WT TR TR : nspection...21 WR ST...23 xploded View...23 Removal and nstallation...23 nspection...24 RG GR G W W : xploded View W : Removal and nstallation W : isassembly and ssembly W : nspection...33 W...34 W : xploded View...34 W : Removal and nstallation...36 W : isassembly and ssembly...37 W : nspection...43 WR RG U...45 xploded View...45 Removal and nstallation...46 isassembly and ssembly...46 nspection...49 YRU W W : xploded View...51 W...51 W : xploded View...52 SRV T STS (SS)

2 SRV T STS (SS) General Specifications Steering Wheel xial nd lay and lay Steering Wheel Turning orce Steering ngle Steering olumn ength Steering olumn ounting imensions Steering olumn perating Range ower Shaft Sliding Range Rack Sliding orce Rack Stroke Socket Swing orce and Rotating Torque Socket xial nd lay nner Socket ength Relief il ressure

3 S, VRT RSSS (V) TRUSTG < SYT GSS > SYT GSS S, VRT RSSS (V) TRUSTG V Troubleshooting hart : W S (WTUT TR TR) Use the chart below to help you find the cause of the symptom. f necessary, repair or replace these parts. Reference ossible cause and SUST RTS Symptom : pplicable Steering -11, "nspection" -11, "nspection" -33, "2W : nspection" -33, "2W : nspection" -33, "2W : nspection" 2W S (WT TR TR) Use the chart below to help you find the cause of the symptom. f necessary, repair or replace these parts. -11, "nspection" -13, "nspection" -13, "nspection" -13, "hecking" -13, "nspection" -25, "2W : xploded View" -18, "WTUT TR TR : nspection" -17, "WTUT TR TR : xploded View" -25, "2W : xploded View" V in section. V in section. V in X, RX, SU, RSU section. V in WT section. V in WT section. V in X section. V in R section. luid level ir in hydraulic system uter/inner socket ball joint swinging torque uter/inner socket ball joint rotating torque uter/inner socket ball joint end play Steering fluid leakage Steering wheel play Steering gear rack sliding force rive belt looseness mproper steering wheel mproper installation or looseness of tilt lock lever ounting looseness Steering column deformation or damage mproper installation or looseness of steering column Steering linkage looseness RR ST RT X and SUSS TR R W RV ST R oise Shake Vibration Shimmy udder -3

4 S, VRT RSSS (V) TRUSTG < SYT GSS > Reference -11, "nspection" -11, "nspection" -33, "2W : nspection" -33, "2W : nspection" -33, "2W : nspection" -11, "nspection" -13, "nspection" -13, "nspection" -13, "hecking" -13, "nspection" -25, "2W : xploded View" -21, "WT TR TR : nspection" -20, "WT TR TR : xploded View" -25, "2W : xploded View" V in section. V in section. V in X, RX, SU, RSU section. V in WT section. V in WT section. V in X section. V in R section. ossible cause and SUST RTS luid level ir in hydraulic system uter/inner socket ball joint swinging torque uter/inner socket ball joint rotating torque uter/inner socket ball joint end play Steering fluid leakage Steering wheel play Steering gear rack sliding force rive belt looseness mproper steering wheel mproper installation or looseness of tilt lock lever ounting looseness Steering column deformation or damage mproper installation or looseness of steering column Steering linkage looseness RR ST RT X and SUSS TR R W RV ST R Symptom : pplicable Steering oise Shake Vibration Shimmy udder W S (WTUT TR TR) Use the chart below to help you find the cause of the symptom. f necessary, repair or replace these parts. -4

5 S, VRT RSSS (V) TRUSTG < SYT GSS > Reference -11, "nspection" -11, "nspection" -43, "W : nspection" -43, "W : nspection" -43, "W : nspection" -11, "nspection" -13, "nspection" -13, "nspection" -13, "hecking" -13, "nspection" -34, "W : xploded View" -18, "WTUT TR TR : nspection" -17, "WTUT TR TR : xploded View" -34, "W : xploded View" V in section. V in section. V in X, RX, SU, RSU section. V in WT section. V in WT section. V in X section. V in R section. ossible cause and SUST RTS luid level ir in hydraulic system uter/inner socket ball joint swinging torque uter/inner socket ball joint rotating torque uter/inner socket ball joint end play Steering fluid leakage Steering wheel play Steering gear rack sliding force rive belt looseness mproper steering wheel mproper installation or looseness of tilt lock lever ounting looseness Steering column deformation or damage mproper installation or looseness of steering column Steering linkage looseness RR ST RT X and SUSS TR R W RV ST R Symptom : pplicable Steering oise Shake Vibration Shimmy udder W S (WT TR TR) Use the chart below to help you find the cause of the symptom. f necessary, repair or replace these parts. -5

6 S, VRT RSSS (V) TRUSTG < SYT GSS > Reference -11, "nspection" -11, "nspection" -43, "W : nspection" -43, "W : nspection" -43, "W : nspection" -11, "nspection" -13, "nspection" -13, "nspection" -13, "hecking" -13, "nspection" -34, "W : xploded View" -21, "WT TR TR : nspection" -20, "WT TR TR : xploded View" -34, "W : xploded View" V in section. V in section. V in X, RX, SU, RSU section. V in WT section. V in WT section. V in X section. V in R section. ossible cause and SUST RTS luid level ir in hydraulic system uter/inner socket ball joint swinging torque uter/inner socket ball joint rotating torque uter/inner socket ball joint end play Steering fluid leakage Steering wheel play Steering gear rack sliding force rive belt looseness mproper steering wheel mproper installation or looseness of tilt lock lever ounting looseness Steering column deformation or damage mproper installation or looseness of steering column Steering linkage looseness RR ST RT X and SUSS TR R W RV ST R Symptom : pplicable Steering oise Shake Vibration Shimmy udder -6

7 < RUT > RUT RUTS RUTS recaution for Supplemental Restraint System (SRS) "R G" and "ST T R-TSR" : The Supplemental Restraint System such as R G and ST T R-TSR, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. nformation necessary to service the system safely is included in the SRS RG and ST T of this Service anual. WRG: To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized SS/T dealer. mproper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. or removal of Spiral able and ir ag odule, see the SRS RG. o not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service anual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. recaution ecessary for Steering Wheel Rotation after attery isconnect : T: efore removing and installing any control units, first turn the push-button ignition switch to the position, then disconnect both battery cables. fter finishing work, confirm that all control unit connectors are connected properly, then re-connect both battery cables. lways use SUT- to perform self-diagnosis as a part of each function inspection after finishing work. f a T is detected, perform trouble diagnosis according to self-diagnosis results. This vehicle is equipped with a push-button ignition switch and a steering lock unit. f the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. f turning the steering wheel is required with the battery disconnected or discharged, follow the procedure below before starting the repair operation. RT RUR 1. onnect both battery cables. T: Supply power using jumper cables if battery is discharged. 2. Turn the push-button ignition switch to position. (t this time, the steering lock will be released.) 3. isconnect both battery cables. The steering lock will remain released with both battery cables disconnected and the steering wheel can be turned. 4. erform the necessary repair operation. 5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn the push-button ignition switch from position to position, then to position. (The steering wheel will lock when the push-button ignition switch is turned to position.) 6. erform self-diagnosis check of all control units using SUT-. Service otice or recautions for Steering System : n case of removing steering gear assembly, make the final tightening with grounded and unloaded vehicle condition, and then check wheel alignment. bserve the following precautions when disassembling. -7

8 < RUT > RUTS - efore disassembly, thoroughly clean the outside of the unit. - isassembly should be done in a clean work area. t is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. - or easier and proper assembly, place disassembled parts in order on a parts rack. - Use nylon cloth or paper towels to clean the parts; common shop rags can leave lint that might interfere with their operation. - ever reuse non-reusable parts. - efore assembling, apply the specified grease to the directed parts. -8

9 < RRT > RRT RRT RRT Special Service Tools : The actual shapes of ent-oore tools may differ from those of special service tools illustrated here. Tool number (ent-oore o.) Tool name ( ) Steering wheel puller escription Removing steering wheel 3127S000 ( ) reload gauge ZZ0819 nspecting sliding torque, steering torque, and rotating torque for ball joint ZZ0806 V ( ) Teflon ring correcting tool a: 50 mm (1.97 in) b: 36 mm (1.42 in) c: 100 mm (3.94 in) nstalling rack Teflon ring S-T550 V ( ) reload adapter nspecting rotating torque ( ) rift a: 45.1 mm (1.776 in) dia. b: 59.0 mm (2.323 in) dia. ZZ0824 nstalling oil pump oil seal ZZ0881-9

10 < RRT > RRT Tool number (ent-oore o.) Tool name V (-26357) il pressure gauge escription easuring oil pump relief pressure S-T547 V (-33914) il pressure gauge adapter easuring oil pump relief pressure S-T542 ommercial Service Tool : Tool number Tool name ower tool escription oosening bolts and nuts

11 < -V T > WR RG U -V T WR RG U nspection U V 1. heck fluid level with engine stopped. 2. nsure that fluid level is between and X. 3. luid levels at T and are different. o not confuse them. : T : luid temperature ( ) : luid temperature 0 30 (32 86 ) Recommended fluid luid capacity : Refer to -10, "luids and ubricants". : Refer to -53, "General Specifications". The fluid level should not exceed the X line. xcessive fluid causes fluid leakage from the cap. ever reuse drained power steering fluid. U G heck hydraulic connections for fluid leakage, cracks, damage, looseness, or wear. 1. Run the engine until the fluid temperature reaches 50 to 80 (122 to 176 ) in reservoir tank, and keep engine speed idle. 2. Turn steering wheel several times from full left stop to full right stop. 3. old steering wheel at each lock position for five seconds and carefully check for fluid leakage. ever hold the steering wheel in a locked position for more SG0506 than 10 seconds. (There is the possibility that power steering oil pump assembly may be damaged.) 4. f fluid leakage at connections is noticed, then loosen flare nut and then retighten. o not overtighten connector as this can damage -ring, washer and connector. 5. f fluid leakage from oil pump is noticed, check oil pump. Refer to -49, "nspection". 6. heck steering gear boots for accumulation of fluid leaked from steering gear. R G YRU SY f air bleeding is not complete, the following symptoms can be observed. ubbles are created in reservoir tank. licking noise can be heard from oil pump. xcessive buzzing in the oil pump. T: luid noise may occur in the steering gear or oil pump. This does not affect performance or durability of the system. 1. Turn steering wheel several times from full left stop to full right stop with engine off. ill reservoir tank with a sufficient amount of fluid so that fluid level is not below the line while turning steering wheel. 2. Start the engine and hold steering wheel at each lock position for 3 second at idle to check for fluid leakage. SG

12 WR RG U < -V T > 3. Repeat step 2 above several times at approximately 3 second intervals. ever hold the steering wheel in a locked position for more than 10 seconds. (There is the possibility that oil pump may be damaged.) 4. heck fluid for bubbles and white contamination. 5. Stop the engine if bubbles and white contamination do not drain out. erform step 2 and 3 above after waiting until bubbles and white contamination drain out. 6. Stop the engine, and then check fluid level. -12

13 < -V T > RG W nspection RG W : RG W X Y 1. heck installation conditions of steering gear assembly, front suspension assembly, axle and steering column assembly. 2. heck if movement exists when steering wheel is moved up and down, to the left and right and to the axial direction. Steering wheel axial end play 3. heck the following items when steering wheel axial end play is out of the standard. heck the steering column assembly mounting condition. Refer to -17, "WTUT TR TR : xploded View" (without electric motor), -20, "WT TR TR : xploded View" (with electric motor). heck steering gear assembly mounting condition for looseness. Refer to -25, "2W : xploded View" (2W models), -34, "W : xploded View" (W models). RG W Y : Refer to -53, "Steering Wheel xial nd lay and lay". 1. Turn steering wheel so that front wheels come to the straight-ahead position. 2. Start the engine and lightly turn steering wheel to the left and right until front wheels start to move. 3. easure steering wheel movement on the outer circumference. Steering wheel play : Refer to -53, "Steering Wheel xial nd lay and lay". 4. heck the following items when steering wheel play is out of the standard. heck backlash for each joint of steering column assembly. heck installation condition of steering gear assembly. UTR ST RG W 1. heck that steering gear assembly, steering column assembly and steering wheel are installed in the correct position. 2. erform neutral position inspection after wheel alignment. Refer to SU-8, "nspection" (2W models), SU-27, "nspection" (W models). 3. Set the vehicle to the straight-ahead position and confirm steering wheel is in the neutral position. 4. oosen outer socket lock nut and turn inner socket to left and right equally to make fine adjustments if steering wheel is not in the neutral position. RG W TURG R 1. ark the vehicle on a level and dry surface, set parking brake. 2. Tires need to be inflated normal pressure. Refer to WT-104, "Tire ir ressure". 3. Start the engine. 4. ring power steering fluid up to adequate operating temperature. luid temperature : ( ) -13

14 < -V T > RG W 5. heck steering wheel turning force when steering wheel has been turned 540 from neutral position. Steering wheel turning force T: ultiply the distance () from the hook of spring balance to the center of steering wheel by the measurement value with a spring balance. SG0027ZZ 6. f steering wheel turning force is out of the specification, check rack sliding force and relief hydraulic pressure of oil pump. Regarding relief hydraulic pressure of oil pump, refer to -49, "nspection". R SG R 1. isconnect lower joint and steering knuckle from steering gear assembly. Refer to -25, "2W : xploded View" (2W models), -34, "W : xploded View" (W models). 2. Start and run the engine at idle to make sure steering fluid has reached normal operating temperature. luid temperature : Refer to -53, "Steering Wheel Turning orce". 3. While pulling outer socket slowly in ±11.5 mm (±0.453 in) range from neutral position, make sure rack sliding force is within specification. Rack sliding force : ( ) : Refer to -54, "Rack Sliding orce". 4. f rack sliding force is not within specification, overhaul steering gear assembly. RT W TURG G 1. heck front wheel turning angle after toe-in inspection. Refer to SU-8, "nspection" (2W models), SU- 27, "nspection" (W models). 2. lace front wheels on turning radius gauges and rear wheels on stands, so that vehicle can be level. 3. heck the maximum inner and outer wheel turning angles for and R road wheels. S

15 < -V T > RG W 4. With the engine at idle, turn steering wheel from full left stop to full right stop and measure the turning angles. nner wheel (ngle: ) uter wheel (ngle: ) : Refer to -53, "Steering ngle". : Refer to -53, "Steering ngle". 5. heck the following items when turning angle is out of the standard. a. heck the neutral position of the rack stroke (). SG0055 : Refer to -54, "Rack Stroke". b. isassemble steering gear assembly to check the cause that rack stroke is outside of the standard. Steering angles are not adjustable. heck steering gear SG0629 assembly, steering column assembly and front suspension components for wear or damage if any of the turning angles are different from the specified value. Replace any of them, if any non-standard condition exists. -15

16 < -V RR > -V RR RG W xploded View RG W : SG0340G 1. Steering wheel Refer to G-4, "omponents" for symbols in the figure. Removal and nstallation : RV T: When reconnecting spiral cable, fix cable with a tape so that fixing case and rotating part keep aligned. This will omit neutral position alignment procedure during spiral cable installation. 1. Set the vehicle to the straight-ahead position. 2. Remove driver air bag module. Refer to SR-8, "xploded View". 3. Remove steering wheel lock nut after steering is locked. 4. Remove steering wheel with the steering wheel puller () [S: ( )]. SG0341ZZ T ote the following, and install in the reverse order of removal. ever twist spiral cable freely on excessively after it becomes tight (doing so may cause the cable to tear off). T: heck the spiral cable neutral position after replacing or rotating spiral cable. Refer to SR-6, "Removal and nstallation". -16

17 < -V RR > RG U WTUT TR TR RG U WTUT TR TR : xploded View : Steering column assembly 2. lip 3. lip 4. Spring 5. Upper joint 6. racket Refer to G-4, "omponents" for symbols in the figure. WTUT TR TR : Removal and nstallation RV 1. Set the vehicle to the straight-ahead position. 2. lace the tilt to the highest level. lace the telescopic to the longest level. 3. Remove driver air bag module. Refer to SR-8, "xploded View". 4. Remove steering wheel. Refer to -16, "xploded View". 5. Remove the instrument driver lower panel. Refer to -11, "xploded View". 6. Remove the steering column cover. Refer to -11, "xploded View". 7. Remove spiral cable. Refer to SR-6, "xploded View". 8. Remove combination switch. Refer to S-85, "xploded View". 9. Remove instrument driver lower panel. Refer to -11, "xploded View". 10. Remove knee protector (1). SG0343G :

18 < -V RR > RG U : olt 11. Remove combination meter. Refer to W-162, "xploded View". 12. isconnect each switch harness connectors installed to steering column assembly. 13. Remove the upper joint mounting bolt and nut (lower shaft side), and separate the joint from lower shaft. 14. Remove steering column assembly. ever give axial impact to steering column assembly during removal. ever move steering gear assembly when removing steering column assembly. T ote the following, and install in the reverse order of removal. ake sure there is no space between clip (1) and steering column assembly (2). ever reuse the clip. SG0344ZZ SG0346ZZ Tighten the mounting bolts and nuts in the order shown in the figure when installing the steering column assembly. e careful of the following points when installing the steering column assembly. ever give axial impact to steering column assembly during installation. ever move steering gear assembly. ever reuse the joint mounting nut (lower shaft side). djust neutral position of steering angle sensor. Refer to R-8, "UT RG G SSR UTR ST : Special Repair Requirement". WTUT TR TR : nspection SG0349ZZ : ST TR RV heck each part of steering column assembly for damage or other malfunctions. Replace if necessary. easure steering column assembly rotating torque using a preload gauge [S: 3127S000 ( )]. Replace steering column assembly if outside the standard. Rotating torque : Refer to -53, "Steering olumn perating Range". -18

19 < -V RR > RG U easure the length () as shown, if vehicle has been involved in a minor collision. Replace steering column assembly if out side the standard. : Refer to -53, "Steering olumn ength". nstall the bracket (1) and steering column housing (2) so that the clearance () is within the specified range as described below. Replace steering column assembly if out side the standard. SG0350ZZ : Refer to -53, "Steering olumn ounting imensions". SG0351ZZ ST TR T heck each part of steering column assembly for damage or other malfunctions. Replace if necessary. heck the steering wheel play, neutral position steering wheel, steering wheel turning force, and front wheel turning angle. Refer to -13, "nspection". heck tilt and telescopic mechanism operating range tilt operating range (1), telescopic operating range (2) as shown in the figure. 1 2 WT TR TR : Refer to -53, "Steering olumn perating Range". : Refer to -53, "Steering olumn perating Range". SG0345ZZ -19

20 < -V RR > RG U WT TR TR : xploded View : SG0352G 1. Steering column assembly 2. Spring 3. racket 4. Spacer 5. ollar 6. Upper joint 7. racket Refer to G-4, "omponents" for symbols in the figure. WT TR TR : Removal and nstallation : RV 1. Set the vehicle to the straight-ahead position. 2. lace the tilt to the highest level. lace the telescopic to the longest level. 3. Remove driver air bag module. Refer to SR-8, "xploded View". 4. Remove steering wheel. Refer to -16, "xploded View". 5. Remove instrument driver lower panel. Refer to -11, "xploded View". 6. Remove the steering column cover. Refer to -11, "xploded View". 7. Remove spiral cable. Refer to SR-6, "xploded View". 8. Remove combination switch. Refer to S-85, "xploded View". 9. Remove knee protector (1). -20

21 < -V RR > RG U : olt 10. Remove combination meter. Refer to W-162, "xploded View". 11. isconnect each switch harness connectors installed to steering column assembly. 12. Remove the upper joint mounting bolt and nut (lower shaft side), and separate the joint from lower shaft. 13. Remove steering column assembly. ever give axial impact to steering column assembly during removal. ever move steering gear assembly when removing steering column assembly. ever rotate the lower shaft. T ote the following, and install in the reverse order of removal. ake sure there is no space between clip (1) and steering column assembly (2). SG0344ZZ Tighten the mounting bolts in the order shown in the figure when installing the steering column assembly. ever give axial impact to steering column assembly during installation. ever move steering gear assembly. ever reuse the joint mounting nut (lower shaft side). djust neutral position of steering angle sensor. Refer to R-8, "UT RG G SSR UTR ST : Special Repair Requirement". WT TR TR : nspection SG0354ZZ SG0353ZZ : ST TR RV heck each part of steering column assembly for damage or other malfunctions. Replace if necessary. easure steering column assembly rotating torque using a preload gauge [S: 3127S000 ( )]. Replace steering column assembly if outside the standard. Rotating torque : Refer to -53, "Steering olumn perating Range". -21

22 < -V RR > RG U easure the length () as shown, if vehicle has been involved in a minor collision. Replace steering column assembly if out side the standard. : Refer to -53, "Steering olumn ength". SG0355ZZ nstall the bracket (1) and steering column housing (2) so that the clearance () is within the specified range as described below. Replace steering column assembly if out side the standard. : Refer to -53, "Steering olumn ounting imensions". SG0351ZZ ST TR T heck each part of steering column assembly for damage or other malfunctions. Replace if necessary. heck the steering wheel play, neutral position steering wheel, steering wheel turning force, and front wheel turning angle. Refer to -13, "nspection". heck tilt and telescopic mechanism operating range tilt operating range (1), telescopic operating range (2) as shown in the figure. 1 2 : Refer to -53, "Steering olumn perating Range". : Refer to -53, "Steering olumn perating Range". SG0356ZZ -22

23 < -V RR > WR ST xploded View WR ST : SG0357G 1. Steering column assembly 2. ollar 3. ole cover seal 4. lamp 5. ole cover 6. ower shaft 7. ower joint Refer to G-4, "omponents" for symbols in the figure. Removal and nstallation RV : Set the vehicle to the straight-ahead position. 2. ix the steering wheel. 3. Remove lower joint fixing bolt (steering gear side). 4. Separate the lower shaft from the steering gear assembly by sliding the slide shaft (: sliding range). Spiral cable may be cut if steering wheel turns while separating steering column assembly and steering gear assembly. e sure to secure steering wheel using string to avoid turning. 5. Remove the accelerator pedal bracket and lever assembly. Refer to -3, "xploded View". 6. Remove the parking brake wire clamp stay. 7. Remove the hole cover mounting nuts. SG0035ZZ 8. Remove the upper joint fixing bolt and nut (lower shaft side). 9. Remove the lower shaft and hole cover. 10. Remove collar, hole cover seal, clamp and hole cover. T ote the following, and install in the reverse order of removal. Spiral cable may be cut if steering wheel turns while separating steering column assembly and steering gear assembly. e sure to secure steering wheel using string to avoid turning. -23

24 < -V RR > WR ST Tighten the clamp to the specified torque and check the clamp length (). : mm ( in) When installing lower joint to steering gear assembly, follow the procedure listed below. - Set rack of steering gear in the neutral position. T: To get the neutral position of rack, turn gear-sub assembly and measure the distance of inner socket, and then measure the intermediate position of the distance. - lign rear cover cap projection () with the marking position of gear housing assembly (). SG0094ZZ - nstall slit part of lower joint () aligning with the rear cover cap projection (). ake sure that the slit part of lower joint () is aligned with rear cover cap projection () and the marking position of gear housing assembly (). djust neutral position of steering angle sensor. Refer to R-8, "UT RG G SSR UTR ST : Special Repair Requirement". heck the following after installation: - heck if steering wheel turns smoothly when it is turned several SG0111ZZ times fully to the end of the left and right. - heck the steering wheel play, neutral position steering wheel, steering wheel turning force, and front wheel turning angle. Refer to -13, "nspection". nspection : olt heck the length () (extended position) of the lower shaft. : Refer to -54, "ower Shaft Sliding Range". heck each part of lower shaft for damage or other malfunctions. Replace if there are. : SG0358ZZ -24

25 < -V RR > RG GR G 2W 2W : xploded View RV RG GR G : SG0038G 1. Steering gear assembly 2. otter pin 3. Rack stay : Vehicle front Refer to G-4, "omponents" for symbols in the figure. SSSY SG0359G 1. ow pressure piping 2. Rear cover cap 3. Gear-sub assembly 4. ower steering solenoid valve 5. -ring 6. djusting screw -25

26 < -V RR > RG GR G 7. Spring 8. Retainer 9. uter socket 10. oot clamp 11. oot 12. nner socket 13. oot clamp (stainless wire) 14. Spacer 15. ylinder tubes 16. Gear housing assembly 17. Rack oil seal 18. Rack assembly 19. Rack Teflon ring 20. nd cover assembly : pply power steering fluid. : pply Genuine iquid Gasket, Three ond 1111 or equivalent. : pply multi-purpose grease. Refer to G-4, "omponents" for symbols not described on the above. 2W : Removal and nstallation RV 1. Set the vehicle to the straight-ahead position. 2. Remove tires with a power tool. 3. Remove front suspension member stay. Refer to SU-9, "xploded View". 4. Remove engine lower cover. Refer to XT-29, "xploded View". 5. Remove cotter pin (1), and then loosen the nut. 6. Remove steering outer socket (2) from steering knuckle (3) so as not to damage ball joint boot (4) using suitable ball joint remover. Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint remover from suddenly coming off. 7. Remove high pressure piping and low pressure piping of hydraulic piping, and then drain power steering fluid. : G Remove power steering solenoid valve harness connector (1). 9. Remove rack stay. Refer to -25, "2W : xploded View". 10. Remove lower joint fixing bolt (steering gear side). SG0360ZZ 11. Separate the lower shaft from the steering gear assembly by sliding the side shaft (: sliding range). Spiral cable may be cut if steering wheel turns while separating steering column assembly and steering gear assembly. e sure to secure steering wheel using string to avoid turning. 12. Remove steering gear assembly. T ote the following, and install in the reverse order of removal. SG0035ZZ -26

27 < -V RR > RG GR G Spiral cable may be cut if steering wheel turns while separating steering column assembly and steering gear assembly. e sure to secure steering wheel using string to avoid turning. Tighten the mounting bolts in the order shown in the figure when installing the steering gear assembly. Temporary tightening: inal tightening: SG0112ZZ When installing suction hoses (1), refer to the figure. ever apply fluid to the hose (1) and tube (2). nsert hose securely until it contacts spool () of tube. eave clearance () when installing clamp (3). : 3 8 mm ( in) When installing lower joint to steering gear assembly, follow the procedure listed below. - Set rack of steering gear in the neutral position. T: To get the neutral position of rack, turn gear-sub assembly and measure the distance of inner socket, and then measure the intermediate position of the distance. - lign rear cover cap projection () with the marking position of gear housing assembly (). : olt - nstall slit part of lower joint () aligning with the rear cover cap projection (). ake sure that the slit part of lower joint () is aligned with rear cover cap projection () and the marking position of gear housing assembly (). fter installation, bleed air from the steering hydraulic system. Refer to -11, "nspection". erform final tightening of nuts and bolts on each part under unladen conditions with tires on level ground when removing steering gear assembly. heck wheel alignment. Refer to SU-8, SG0111ZZ "nspection". djust neutral position of steering angle sensor after checking wheel alignment. Refer to R-8, "U- T RG G SSR UTR ST : Special Repair Requirement". 2W : isassembly and ssembly SG0118ZZ : SSSY 1. Remove low pressure piping. isassemble and assemble steering gear assembly by fixing the mounting area with a vise using copper plates. lean steering gear assembly with kerosene before disassembling. e careful to avoid splashing or applying any kerosene over connector of discharge port or return port. 2. Remove cylinder tubes from gear housing assembly. 3. Remove rear cover cap from gear-sub assembly. -27

28 < -V RR > RG GR G 4. easure adjusting screw height, and loosen adjusting screw. ever loosen adjusting screw 2 turns or more. Replace steering gear assembly if adjusting screw is loosened 2 turns or more and it is removed. 5. Remove gear-sub assembly from gear housing assembly. 6. Remove -ring from gear housing assembly. 7. oosen outer socket lock nut, and remove outer socket. 8. Remove boot clamps, and then remove boot from inner socket. SG0624 ever damage inner socket and gear housing assembly when removing boot. nner socket and gear housing assembly must be replaced if inner socket and gear housing assembly are damaged because it may cause foreign material interfusion. 9. Remove inner socket from gear housing assembly. 10. rill out the clinching part of gear housing assembly (end cover assembly side) outer rim with a 3 mm (0.12 in) drill bit. [rill for approximately 1.5 mm (0.059 in) depth.] Remove end cover assembly with a 36 mm (1.42 in) open head (suitable tool). ever damage rack assembly surface when removing. Rack assembly must be replaced if damaged because it may cause fluid leakage. 12. ull rack assembly together with rack oil seal (outer side) out from gear housing assembly. ever damage cylinder inner wall when remove rack assembly. Gear housing assembly must be replaced if damaged because it may cause fluid leakage. 13. eat rack Teflon ring to approximately 40 (104 ) with a dryer, and remove rack Teflon ring from rack assembly. ever damage rack assembly. Rack assembly must be replaced if damaged because it may cause fluid leakage. S081 SG

29 < -V RR > RG GR G 14. ush rack oil seal inside with a 29 mm (1.14 in) socket and an extension bar to push out rack oil seal (inner side) from gear housing assembly. ever damage gear housing assembly and cylinder inner wall. Gear housing assembly must be replaced if damaged because it may cause fluid leakage. SG0179 SSY 1. eat rack Teflon ring to approximately 40 (104 ) with a dryer. ssemble it to mounting groove of rack assembly. ever reuse rack Teflon ring. SG nstall the Teflon ring correcting tool [S: V ( )] from tooth side of rack to fit rack Teflon ring on rack. ompress the ring with tool. 3. pply recommended grease to rack oil seal, and then install rack oil seal in the following procedure. Then assemble rack assembly to gear housing assembly. nstall rack oil seal in a direction so that the lip of inner oil seal and the lip of outer oil seal face each other. ever damage retainer sliding surface by rack assembly. Replace gear housing assembly if damaged. ever damage gear housing assembly inner wall by rack assembly. Gear housing assembly must be replaced if damaged because it may cause fluid leakage. ever reuse rack oil seal. SG0154 SG

30 < -V RR > RG GR G a. Wrap an sheet [approximately 70 mm (2.76 in) 100 mm (3.94 in)]. round rack assembly teeth to avoid damaging rack oil seal (inner). nstall rack oil seal over sheet. Then, pull sheet along with rack oil seal until they pass rack assembly teeth, and remove sheet. SG0155 b. nsert rack oil seal (inner) into rack assembly piston (rack Teflon ring). c. ush retainer to adjusting screw side by hand, and move the rack assembly inside the gear housing assembly so that the rack oil seal (inner) can be pressed against the gear housing assembly. SG0671 d. Wrap an sheet [approximately 70 mm (2.76 in) 100 mm (3.94 in)]. round the edge to avoid damaging rack oil seal (outer). nstall rack oil seal over sheet. Then, pull oil seal along with sheet until they pass rack edge, and remove sheet. e. nstall end cover assembly to rack edge, and move rack oil seal (outer) until it contacts with gear housing assembly. SG Tighten end cover assembly to specified torque using a 36 mm (1.42 in) open head (suitable tool). ever damage rack assembly. Replace it if damaged because it may cause fluid leakage. S rimp gear housing assembly at one point using a punch as shown in the figure so as to prevent end cover assembly from getting loose after tightening end cover assembly. 6. pply recommended fluid to -ring, and then install -ring to gear housing assembly. 7. nstall gear-sub assembly to gear housing assembly. n order to protect oil seal from any damage, insert gearsub assembly straightly. 8. nstall inner socket to gear housing assembly with the following procedure. SG

31 < -V RR > RG GR G a. pply thread sealant into the thread of inner socket. Use Genuine Silicone RTV or equivalent. Refer to G-15, "Recommended hemical roducts and Sealants". 9. Screw inner socket into rack part and tighten at the specified torque. 10. ecide on the neutral position of the rack stroke (). : Refer to -54, "Rack Stroke". 11. nstall rear cover cap to gear sub-assembly. ake sure that the projection of rear cover cap is aligned with the marking position of gear housing assembly. 12. pply recommended thread locking sealant to the thread (2 turns thread), and then screw in the adjusting screw until it reaches height from gear housing assembly measured before disassembling. 13. ove rack assembly 10 strokes throughout the full stroke so that the parts can fit with each other. SG djust pinion rotating torque with the following procedure. a. easure pinion rotating torque within ±180 of neutral position of the rack assembly using Tools. Stop the gear at the point where highest torque is read. SG0624 : reload gauge [S: 3127S000 ( )] : reload adapter [S: V ( )] b. oosen adjusting screw and retighten to 5.4 m (0.55 kg-m, 48 in-lb), and then loosen by 20 to 40. c. easure pinion rotating torque using tools to make sure that the measured value is within the standard. Readjust if the value is outside the standard. Replace steering gear assembly, if the value is outside the standard after readjusting, or adjusting screw rotating torque is 5 m (0.51 kg-m, 44 in-lb) or less. SG1383 inion rotating torque round neutral position (within±100 ) average : m ( kg-m, in-lb) aximum variation : 0.98 m (0.10 kg-m, 9.0 in-lb) SG0936 d. pply recommended liquid gasket to inner socket and turn pinion fully to left with inner socket installed to gear housing assembly. -31

32 < -V RR > RG GR G e. nstall dial gauge at 5 mm (0.20 in) () from the edge of gear housing assembly (1), and tooth point. f. easure vertical movement of rack assembly when pinion is turned clockwise with torque of 19.6 m (2.0 kg-m, 14 ft-lb). Readjust adjusting screw angle if the measured value is outside the standard. Vertical movement : mm ( in) f reading is outside of the specification, readjust screw angle with adjusting screw. SG0104ZZ f reading is still outside of specification, or if the rotating torque of adjusting screw is less than 5 m (0.51 kg-m, 44 in-lb), replace steering gear assembly. ever turn adjusting screw more than twice. Replace steering gear assembly when adjusting screw is removed or turned more than twice. 15. nstall large end of boot to gear housing assembly. 16. nstall small end of boot to inner socket boot mounting groove. 17. nstall boot clamp to boot small end. SG nstall boot clamp to the large side of boot with the following procedure. ever reuse boot clamp. a. Tighten large side of boot with boot clamp (stainless wire). Wire length () : 370 mm (14.57 in) b. Wrap clamp around boot groove for two turns. nsert a flatbladed screwdriver in loops on both ends of wire. Twist 4 to 4.5 turns while pulling them with force of approximately 98 (10 kg, 22 lb). SG0163 c. Twist boot clamp as shown. ay attention to relationship between winding and twisting directions. SG

33 < -V RR > RG GR G d. Twisted area () of clamp is in the opposite side of adjusting screw (1) as shown in the figure (to prevent contact with other parts). e. ent cut end of the wire toward rack axial as shown in the figure after twisting the wire 4 to 4.5 turns so that cut end does not contact with boot. eep gap from cylinder tube 5 mm (0.20 in) or more. SG0361ZZ nstall cylinder tubes to gear housing assembly. 20. nstall low pressure piping. 21. djust inner socket to standard length (), and then tighten lock nut to the specified torque. heck length again after tightening lock nut. djust toe-in after this procedure. The length achieved after toe-in adjustment is not necessary the above value. 2W : nspection : Refer to -54, "nner Socket ength". SG0167 : ST TR T heck if steering wheel turns smoothly when it is turned several times fully to the end of the left and right. heck the steering wheel play, neutral position steering wheel, steering wheel turning force, and front wheel turning angle. Refer to -13, "nspection". heck the fluid level, fluid leakage, and air bleeding hydraulic system. Refer to -11, "nspection". ST TR SSSY oot heck boot for cracks, and replace it if a malfunction is detected. Rack ssembly heck rack for damage or wear, and replace it if a malfunction is detected. Gear-Sub ssembly heck gear-sub assembly for damage or wear, and replace it if a malfunction is detected. Rotate gear-sub assembly and check for torque variation or rattle, and replace it if a malfunction is detected. Gear ousing ssembly heck gear housing assembly for damage and scratches (inner wall). Replace if there are. uter Socket and nner Socket -33

34 < -V RR > RG GR G heck the following items and replace the component if it does not meet the standard. T SWGG TRQU ook a spring balance at the point shown in the figure and pull the spring balance. ake sure that the spring balance reads the specified value when ball stud and inner socket start to move. Replace outer socket and inner socket if they are outside the standard. (easuring point of outer socket: Stud cotter pin mounting hole) uter socket : Refer to -54, "Socket Swing orce and Rotating Torque". SG0896 (easuring point of inner socket: * mark shown in the figure) nner socket : Refer to -54, "Socket Swing orce and Rotating Torque". T RTTG TRQU ake sure that the reading is within the following specified range using preload gauge () [S: 3127S000 ( )]. Replace outer socket if the reading is outside the specified value. Rotating torque : Refer to -54, "Socket Swing orce and Rotating Torque". SG1382 T X Y pply an axial load of 490 (50 kg, 110 lb) to ball stud. Using a dial gauge, measure amount of stud movement, and then make sure that the value is within the following specified range. Replace outer socket (1) and inner socket (2) if the measured value is outside the standard. W W : xploded View RV uter socket nner socket : Refer to -54, "Socket xial nd lay". : Refer to -54, "Socket xial nd lay". SG0109ZZ :

35 < -V RR > RG GR G SG0039G 1. Steering gear assembly 2. cotter pin : Vehicle front Refer to G-4, "omponents" for symbols in the figure. SSSY SG0362G 1. ow pressure piping 2. Rear cover cap 3. Gear-sub assembly 4. ower steering solenoid valve 5. -ring 6. djusting screw 7. Spring 8. Retainer 9. uter socket 10. oot clamp 11. oot 12. nner socket 13. oot clamp (stainless wire) 14. Spacer 15. ylinder tubes 16. Gear housing assembly 17. Rack oil seal 18. Rack assembly 19. Rack Teflon ring 20. nd cover assembly -35

36 < -V RR > RG GR G : pply power steering fluid. : pply Genuine iquid Gasket, Three ond 1111 or equivalent. : pply multi-purpose grease. Refer to G-4, "omponents" for symbols not described on the above. W : Removal and nstallation RV 1. Set the vehicle to the straight-ahead position. 2. Remove tires with a power tool. 3. Remove engine lower cover and front under cover. Refer to XT-29, "xploded View". 4. Remove front cross bar. Refer to SU-28, "xploded View". 5. Remove cotter pin (1), and then loosen the nut. 6. Remove steering outer socket (2) from steering knuckle (3) so as not to damage ball joint boot (4) using suitable ball joint remover. Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint remover from suddenly coming off. 7. Remove high pressure piping and low pressure piping of hydraulic piping, and then drain power steering fluid. : G Remove steering hydraulic piping bracket from steering gear assembly. : Vehicle front SG0043ZZ 9. Remove power steering solenoid valve harness connector (1). 10. Remove lower joint fixing bolt (steering gear side). SG0363ZZ -36

37 < -V RR > RG GR G 11. Separate the lower shaft from the steering gear assembly by sliding the slide shaft (: sliding range). Spiral cable may be cut if steering wheel turns while separating steering column assembly and steering gear assembly. e sure to secure steering wheel using string to avoid turning. 12. Remove the mounting bolts and nuts of steering gear assembly. 13. Remove steering gear assembly. T ote the following, and install in the reverse order of removal. Spiral cable may be cut if steering wheel turns while separating steering column assembly and steering gear assembly. e sure to secure steering wheel using string to avoid turning. When installing suction hose (1), refer to the figure. ever apply fluid to the hose (1) and tube (2). nsert hose securely until it contacts spool () of tube. eave clearance () when installing clamp (3). : 3 8 mm ( in) SG0035ZZ When installing lower joint to steering gear assembly, follow the procedure listed below. - Set rack of steering gear in the neutral position. T: To get the neutral position of rack, turn gear-sub assembly and measure the distance of inner socket, and then measure the intermediate position of the distance. - lign rear cover cap projection () with the marking position of gear housing assembly (). : olt - nstall slit part of lower joint () aligning with the rear cover cap projection (). ake sure that the slit part of lower joint () is aligned with rear cover cap projection () and the marking position of gear housing assembly (). fter installation, bleed air from the steering hydraulic system. Refer to -11, "nspection". SG0111ZZ erform final tightening of nuts and bolts on each part under unladen conditions with tires on level ground when removing steering gear assembly. heck wheel alignment. Refer to SU-27, "nspection". djust neutral position of steering angle sensor after checking wheel alignment. Refer to R-8, "U- T RG G SSR UTR ST : Special Repair Requirement". W : isassembly and ssembly SG0118ZZ : SSSY 1. Remove low pressure piping. isassemble and assemble steering gear assembly by fixing the mounting area with a vise using copper plates. lean steering gear assembly with kerosene before disassembling. e careful to avoid splashing or applying any kerosene over connector of discharge port or return port. -37

38 < -V RR > RG GR G 2. Remove cylinder tubes from gear housing assembly. 3. Remove rear cover cap from gear-sub assembly. 4. easure adjusting screw height, and loosen adjusting screw. ever loosen adjusting screw 2 turns or more. Replace steering gear assembly if adjusting screw is loosened 2 turns or more and it is removed. 5. Remove gear-sub assembly from gear housing assembly. 6. Remove -ring from gear housing assembly. 7. oosen outer socket lock nut, and remove outer socket. 8. Remove boot clamps, and then remove boot from inner socket. SG0624 ever damage inner socket and gear housing assembly when removing boot. nner socket and gear housing assembly must be replaced if inner socket and gear housing assembly are damaged because it may cause foreign material interfusion. 9. Remove inner socket from gear housing assembly. 10. rill out the clinching part of gear housing assembly (end cover assembly side) outer rim with a 3 mm (0.12 in) drill bit. [rill for approximately 1.5 mm (0.059 in) depth.] Remove end cover assembly with a 36 mm (1.42 in) open head (suitable tool). ever damage rack assembly surface when removing. Rack assembly must be replaced if damaged because it may cause fluid leakage. 12. ull rack assembly together with rack oil seal (outer side) out from gear housing assembly. ever damage cylinder inner wall when remove rack assembly. Gear housing assembly must be replaced if damaged because it may cause fluid leakage. 13. eat rack Teflon ring to approximately 40 (104 ) with a dryer, and remove rack Teflon ring from rack assembly. ever damage rack assembly. Rack assembly must be replaced if damaged because it may cause fluid leakage. S081 SG

39 < -V RR > RG GR G 14. ush rack oil seal inside with a 29 mm (1.14 in) socket and an extension bar to push out rack oil seal (inner side) from gear housing assembly. ever damage gear housing assembly and cylinder inner wall. Gear housing assembly must be replaced if damaged because it may cause fluid leakage. SG0179 SSY 1. eat rack Teflon ring to approximately 40 (104 ) with a dryer. ssemble it to mounting groove of rack assembly. ever reuse rack Teflon ring. SG nstall the Teflon ring correcting tool [S: V ( )] from tooth side of rack to fit rack Teflon ring on rack. ompress the ring with tool. 3. pply recommended grease to rack oil seal, and then install rack oil seal in the following procedure. Then assemble rack assembly to gear housing assembly. nstall rack oil seal in a direction so that the lip of inner oil seal and the lip of outer oil seal face each other. ever damage retainer sliding surface by rack assembly. Replace gear housing assembly if damaged. ever damage gear housing assembly inner wall by rack assembly. Gear housing assembly must be replaced if damaged because it may cause fluid leakage. ever reuse rack oil seal. SG0154 SG