1987 MAZDA 626 Workshop Manual

MANUAL STEERING 1 0
Disassembly Note
Steering gear and linkage
Secure the gear and linkage in a vise.
Caution
Insert protective material (such as copper
plates) in the jaws of the vise.
86U10X-089
Tie-rod ends
Before removing the tie-rod ends, make a mark for
proper installation.
86U10X-090
Tie-rods
Remove the tie-rods.
1. Uncrimp the washer as shown in the figure.
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2. Secure the rack in a vise and remove the tie-rod.
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10 MANUAL STEERING
Adjust cover
1. Loosen the locknut, and remove the adjust cover
with the SST.
2. Remove the spring, friction block, dish springs
holder, and needle roller assembly.
86U10X-093
Pinion
Gently grasp the serrated part of the pinion and pull
it out of the gear housing.
Caution
If the pinion is difficult to remove, gently tap
the gear housing with a plastic hammer while
pulling.
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Rack
Remove the rack by taking it out in the direction indi-
cated by the arrow.
Caution
Do not damage the rack bushing with the edge
of the rack gear.
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Bearing (lower)
Heat the housing in water to about 80°C (176°F); then
tap the end of the housing with a wooden hammer
to remove the bearing.
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MANUAL STEERING 1 0
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Spring Friction block
Holder
Needle roller
Roller
Bushing
Break the bushing and remove it.
Caution Be careful not to damage the gear housing.
INSPECTION
Check the following and replace any faulty parts.
1. Damaged mounting rubber or bracket
2. Cracked, worn teeth, or damaged pinion
3. Loose, noisy, or sticking bearing in gear housing
4. Cracked or damaged gear housing
5. Worn rack and housing bushing
6. Tie-rod ball-joint operation and looseness
7. Bent tie-rods or tie-rod ends
8. Cracked, worn teeth, or damaged rack
9. Runout of rack
Runout: 0.30 mm (0.012 in) max.
10. Worn or damaged roller and friction block
11. Bearing operation
12. Cracked or damaged holder
13. Weak or damaged spring
Note
If the needle bearing must be replaced, re-
place the roller assembly.
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10 MANUAL STEERING
14. Damaged dish springs
ASSEMBLY
Torque Specifications
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39—59 N-m (4.0—6.0 m-kg, 29—43 ft-lb)
49-69 N-m (5.0—7.0 m-kg, 36—51 ft-l
& S
78—98 N-m (8.0—10.0 m-kg, 58—72 ft-lb)
— 69—78 N-m (7.0—8.0 m-kg, 51—58 ft-lb)
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MANUAL STEERING 1 0
86U10X-103
86U10X-104
86U10X-105
1. Install the mounting rubber and bracket.
2. Install the bushing.
Align A with B and press the bushing into the gear
housing until it is fully seated.
3. Press in the lower bearing.
Caution
a) Before pressing in, put grease (lithium base,
NLGI No. 2) in the bearing and bearing bore.
b) Install the bearing in the proper direction. c) Use the pinion to press the bearing in.
4. Fill or coat the following points with grease (lithi-
um base, NLGI No. 2) before assembly.
a) Pinion bearing and teeth
b) Inside gear housing
c) Oil seal lip
d) Roller surface
e) Holder
f) Friction block surface
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10 MANUAL STEERING
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86U10X-108
Pinion^ -1
Notch A Y
COSSSSW1
Rack
Central position
86U10X-109
g) Inner surface of housing rack bushing
h) Rack gear and outer circumference of rack shaft
L = 180 mm (7.09 in)
i) Tie-rod ball-joint
j) Inside left and right boots
Caution
Be careful not to fill the ventilation holes in
the rack shaft with grease.
5. Carefully install the rack in the direction of the
arrow.
6. Set the notch of the teeth of the rack at the pinion
position, then insert the pinion.
Caution
This notch is used for adjustment of the pin-
ion bearing preload without the pinion en-
gaged with the rack.
7. Install the upper bearing, and then screw on the
rear cover.
Caution
a) Apply sealant to the threads of the rear
cover.
b)Do not install the oil seal.
c) Screw on the rear cover with the SST.
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MANUAL STEERING 1 0
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AJPC
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8. Tighten the rear cover so that the torque of the pin-
ion is approx 400 g (14.1 oz). Check with the SST
and a pull gauge.
Caution
Before measuring the torque, rotate the pin-
ion to the left and right a few times to seat the
bearing.
9. Loosen the rear cover and readjust the pinion
torque to 300 g (10.6 oz). Tighten the locknut.
Tightening torque:
49—69 Nm (5,0—7,0 m-kg, 36—51 ft-lb)
Caution
Recheck the pinion torque after tightening the
locknut. If it is not within 200—350 g (7—12.3
oz), loosen the locknut and adjust once again.
10. Carefully move the rack so that the pinion is set
to the center (neutral position) of the rack gear.
11. Install the roller assembly, needle roller, holder, dish
springs, friction block, and spring.
Caution
Install the roller bearing so that it correctly
contacts the rack.
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10 MANUAL STEERING
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86U10X-116
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Dust Cover
)
2
Oil seal
is Nm
sn n
12. Torque the adjust cover to 9.8 N-m (1 m-kg,
7.2 ft-lb), then loosen it 25°—45°. Secure the ad-
just cover with the locknut and the SST.
Locknut tightening torque:
39—59 N-m (4.0—6.0 m-kg, 29—43 ft-lb)
Note
Apply sealant to the threads of the adjust cov-
er before installing.
13. Measure the pinion torque with the SST.
Center position ± 90°
Pull gauge reading:
1,000—1,400 g (35—50 oz)
Any other position
Pull gauge reading:
less than 1,700 g (60 oz)
14. Mark the positions of the rack grooves of the left
tie-rod for staking.
15. Install the new washer on the left tie-rod, and in-
stall the tie-rod.
Tightening torque:
78—98 N-m (8.0—10.0 m-kg, 58—72 ft-lb)
16. Stake the washer in two places.
17. Use a pipe to press in the oil seal until it is flush
with the end of the rear cover.
18. Slide on the dust cover so that it fits into the pinion
groove.
19. Press in the boot support. Be sure that it fits tightly.
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