COMPONENTS (KOYO Type)

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1 STEERING SR55 COMPONENTS (KOYO Type) DISASSEMBLY OF STEERING GEAR HOUSING 1. CLAMP GEAR HOUSING IN VISE Using SST, secure the steering gear in a vise. SST REMOVE RIGHT AND LEFT TURN PRESSURE TUBES Using SST, remove the pressure tubes. SST

2 SR56 STEERING 3. REMOVE TIE ROD ENDS (a) Loosen the lock nut and place matchmarks on the tie rod end and rack end. (b) Remove the tie rod ends and lock nuts. 4. REMOVE RACK BOOTS (a) Using a screwdriver, remove the clips and clamps. (b) Remove the rack boots. NOTICE: Be careful not to damage the rack boots and rack housing. 5. REMOVE RACK ENDS AND CLAW WASHERS (a) Unstake the claw washers. NOTICE: Avoid any impact to the rack. (b) Using SST, remove the rack ends. SST ( ) ( ) (c) Mark the left and right rack ends accordingly. (d) Remove the claw washers. 6. REMOVE RACK GUIDE SPRING CAP LOCK NUT Using SST, remove the rack guide spring cap lock nut. SST

3 STEERING SR57 7. REMOVE RACK GUIDE SPRING CAP Using SST, remove the rack guide spring cap. SST REMOVE RACK GUIDE SPRING AND RACK GUIDE 9. REMOVE RACK HOUSING CAP 10. REMOVE SELFLOCKING NUT Using SST to hold the control valve, remove the self locking nut. SST REMOVE DUST COVER 12. REMOVE CONTROL VALVE HOUSING (a) Place matchmarks on the valve housing and rack housing. (b) Remove the two bolts. (c) Pull out the valve with the valve housing. (d) Remove the gasket from the rack housing. 13. REMOVE CONTROL VALVE FROM HOUSING (a) Tap out the control valve with the oil seal. (b) Remove the oil seal from the control valve.

4 SR58 STEERING 14. REMOVE CYLINDER END STOPPER (a) Using SST, turn the cylinder end stopper clockwise until the wire end comes out. SST (b) Using SST, turn the cylinder end stopper counterclockwise, and remove the wire. SST (c) Pull out the cylinder end stopper. 15. REMOVE RACK BUSHING AND RACK (a) Remove the rack with the rack bushing. (b) Remove the bushing from the rack. (c) Remove the Oring from the bushing. 16. REMOVE CYLINDER HOUSING OIL SEAL AND SPACER Using SST, drive out the spacer and oil seal. SST and NOTICE: Do not damage the rack housing.

5 STEERING SR59 INSPECTION AND REPAIR OF GEAR HOUSING COMPONENTS 1. INSPECT RACK (a) Check the rack for runout and for tooth wear or damage. (b) Check the back surface for wear or damage. If faulty, replace it. Maximum runout: 0.3 mm (0.012 in.) 2. IF NECESSARY, REPLACE CONTROL VALVE HOUSING OIL SEAL AND UPPER BEARING (a) Using snap ring pliers, remove the snap ring. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the control valve housing. (c) Using SST, press out the upper bearing. SST ( ) ( ) (d) Using SST, press in a new upper bearing as shown. SST ( ) ( )

6 SR60 STEERING (e) Using SST and plastic hammer, tap in a new oil seal. SST ( ) ( ) (f) Coat the oil seal lip with power steering fluid. (g) Using snap ring pliers, install the snap ring. 3. IF NECESSARY, REPLACE CONTROL VALVE LOWER BEARING AND CENTER BEARING (a) Using SST, press out the lower bearing. SST ( ) (b) Using SST, press out the center bearing. SST (c) Using SST, press in a new center bearing as shown. SST ( ) (d) Using SST, press in a new lower bearing. SST ( )

7 STEERING SR61 4. IF NECESSARY, REPLACE RACK BUSHING OIL SEAL (a) Using SST, remove the oil seal. SST ( ) (b) Coat a new oil seal with the power steering fluid. (c) Using a plastic hammer, tap in a new oil seal as shown. 5. IF NECESSARY, REPLACE TEFLON RING AND ORING (a) Remove the teflon ring and 0ring. NOTICE: Be careful not to damage the steering rack. (b) Coat the Oring with power steering fluid and install it. (c) Coat a new teflon ring with power steering fluid. (d) Install the teflon ring to SST and expand. SST ( ) (e) Install the expanded teflon ring to the steering rack and snug it down with your fingers. (f) Coat the teflon ring with power steering fluid, and carefully slide the tapered end of SST over the teflon ring to seat the ring. SST ( )

8 SR62 STEERING 6. IF NECESSARY, REPLACE CONTROL VALVE TEFLON RINGS (a) Using a screwdriver, remove the teflon rings. NOTICE: Be careful not to damage the control valve. (b) Install new teflon rings to SST and expand them. SST (c) Install the expanded teflon rings to the control valve and snug them down with your fingers. (d) Coat the teflon rings with power steering fluid, and carefully slide the tapered end of SST over the teflon rings to seat the rings. SST

9 STEERING SR63 ASSEMBLY OF STEERING GEAR HOUSING (See page SR55) 1. COAT POWER STEERING FLUID OR GREASE ON FOLLOWING PARTS: 2. INSTALL CYLINDER HOUSING OIL SEAL AND SPACER Install a new oil seal and spacer to SST, and drive in them with a plastic hammer. SST and INSTALL RACK (a) Install SST to the rack. HINT: If necessary, scrape the burrs off the rack teeth end and burnish. SST

10 SR64 STEERING (b) Coat SST with power steering fluid. (c) Insert the rack into the cylinder. (d) Remove SST. SST INSTALL RACK BUSHING (a) Coat a new Oring with power steering fluid and install it to the bushing. (b) To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid. (e) Install the bushing by pushing it into the cylinder in the direction shown in drawing, without tilting. 5. INSTALL CYLINDER END STOPPER (a) Push in the cylinder end stopper until the wire installation hole appears. (b) Insert a new wire end into the hole. (c) Using SST, turn the cylinder end stopper clockwise until the wire end disappears. SST AIR TIGHTNESS TEST (a) Install SST to the union of the cylinder housing. SST (b) Apply 400 mmhg (15.75 in.hg, 53.3 kpa) of vacuum for about 30 seconds. (c) Check that there is no change in the vacuum.

11 STEERING SR65 7. INSTALL CONTROL VALVE (a) Coat the teflon rings with power steering fluid. (b) Install the control valve into the housing. NOTICE: Be careful not to damage the teflon rings and oil seal. 8. INSTALL OIL SEAL (a) Coat a new oil seal with power steering fluid. (b) Using SST, install the oil seal as shown. SST INSTALL DUST COVER 10. INSTALL CONTROL VALVE HOUSING (a) Place a new gasket on the rack housing. (b) Align the marks on the valve housing and rack housing. (c) Torque the two bolts. Torque: 185 kgcm (13 ftib, 18 Nm) 11. INSTALL SELFLOCKING NUT Using SST to hold the control valve, install a new selflocking nut. SST Torque: 250 kgcm (18 ftib, 25 Nm) 12. INSTALL RACK HOUSING CAP (a) Apply sealant to 2 or 3 threads of the bolt end. Sealant: Part No , THREE BOND 1344, LOCTITE 242 or equivalent (b) Install the rack housing cap. Torque: 600 kgcm (43 ftib, 59 Nm)

12 SR66 STEERING (c) Using a center punch, stake the housing at two place. 13. INSTALL RACK GUIDE AND RACK GUIDE SPRING 14. ADJUST TOTAL PRELOAD (a) Apply sealant to 2 or 3 threads of the spring cap. Sealant: Part No , THREE BOND 1344, LOCTITE 242 or equivalent (b) Using SST, install and torque the spring cap. SST Torque: 250 kgcm (18 ftib, 25 Nm) (c) Using SST, return the rack guide spring cap 121. SST (d) Turn the control valve shaft right and left one or two times. (e) Loosen the spring cap until the rack guide compression spring is not functioning. (f) Using SST and a torque meter, tighten the rack guide spring cap until the preload is within specification. SST and Preload (turning): 912 kgcm ( in. lb, Nm) 15. INSTALL RACK GUIDE SPRING CAP LOCK NUT (a) Apply sealant to 2 or 3 threads of the lock nut. Sealant: Part No , THREE BOND 1344, LOCTITE 242 or equivalent (b) Using SST, install and torque the lock nut. SST and Torque: 540 kgcm (39 ftib, 53 Nm) HINT: Use a torque wrench with a fulcrum length of 425 mm (16.73 in.). (c) Recheck the total preload.

13 STEERING SR INSTALL CLAW WASHERS AND RACK ENDS (a) Install a new claw washer. (b) Using SST, install and torque the rack end. SST t y ( ) Torque: 730 kgcm (53 ftib, 72 Nm) HINT: Use a torque wrench with a fulcrum length of 340 mm ( in.). (c) Using a brass bar and hammer, stake the claw washer. 17. INSTALL RACK BOOTS (a) Insure that the tube hole is not clogged with grease. HINT: If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel turned. (b) Install the boots. HINT: Be careful not to damage or twist the boots. (c) Install the clamps. (d) Install the clips with the ends facing outward. 18. INSTALL TIE ROD ENDS (a) Screw the lock nuts and tie rod ends onto the rack ends until the matchmarks are aligned. (b) After adjusting toein, torque the lock nut. Torque: 570 kgcm (41 ftib, 56 Nm)

14 SR68 STEERING 19. INSTALL RIGHT AND LEFT TURN PRESSURE TUBES (a) Install four new Orings to the tubes. (b) Using SST, install the tubes. SST Torque: 110 kgcm (8 ftib, 11 Nm) HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

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