1995 ISUZU TROOPER Workshop Manual

lJ
Fig. 381-9
l••f INSTALLATION
6. Gear box (Fig. 381-1 0)
l£tj• Align the setting marks made at removal.
5. Gear box mounting bolt and nut
1~1 Torque N·m (lb·ft) 44 (33)
4. Coupling clamp bolt
~~~ Torque N·m (lb·ft) 25 (18)
3. Pitman arm (Fig. 381·11)
l£tj• Align the notched tooth.
2. Nut
~~~---T-o-rq_u_e __ N_·_m_(_lb-.ft-)~~---2-1_6_(1_5_9_) __ ___
1. Pipe
~~~--T-o-rq_u_e __ N--m----(-lb-.ft-)~-------4-4-(-33_) ____ _
POWER STEERING GEAR AND PUMP 381-7
Fig. 381-10
Fig. 381-11

381-8 POWER STEERING GEAR AND PUMP
POWER STEERING PUMP
<
4
Removal steps
1. Hose, suction
2. Hose,
flexible 3. Adjust bolt 4. Belt 5. Bolt 6. Pump assembly and pulley
7. Pulley
8. Adjust
plate
9. Pump assembly
Installation
steps To install, follow the removal steps in the reverse order.
Fig. 381-12
B REMOVAL
Preparation: • Place a drain pan below the pump.
1. Hose, suction
2. Hose, flexible
3. Adjust bolt
4. Belt
5.
6.
7.
8.
9.
Bolt
Pump assembly and pulley
Pulley
Adjust plate
Pump assembly
1•+1 INSTALLATION
9. Pump assembly
8. Adjust plate
~~~ Torque N·m (lb·ft) 56 (41)
7. Pulley
~~~ Torque N·m (lb·ft)
6. Pump assembly and pulley
5. Bolt
~~~ Torque N·m (lb·ft)
4.
3.
Belt
Adjust bolt
78 (58)
46 (34)
• After adjusting drive belt tension, tighten bolt
to specified torque.
I~I_T_o_rq....:...u_e_N_·_m_(_lb_·ft_)____! ___ 4_6...:..(3_4...:_) __ _
2. Hose, flexible
~~~ Torque N·m (lb·ft) 54 (40)
1. Hose, suction
• Fill and bleed the system. Refer to "Bleeding
the Power Steering System" in this section.

POWER STEERING GEAR AND PUMP 381-9
STEERING GEAR
1.,!,.1 DISASSEMBL V
W CAUTION:
UNIT REPAIR
Fig. 381-13
Yf Do not clamp the steering gear assembly in a vise
by the power cylinder housing.
1. Dust cover
2. Retaining ring
3. Back up ring
4. Oil seal
1) Clean the faces of the extended stub shaft.
2) Plug the hose fitting on the inlet side.
3) Remove the oil seal by blowing compressed
air through the
hole in the outlet side (Fig. 381-
14).
Disassembly steps
1. Dust cover
2. Retaining ring
3. Back up ring
4.
Oil seal 5. Lock nut 6. Top cover assembly
7. 0-ring
8. Sector shaft
9.
Ball-nut and valve housing
assembly
10. 0-ring
11. Seal ring
12. 0-ring
13. Gear
box
Reassembly steps
To reassemble, follow the
disassembly steps in the
reverse order.
Fig. 381-14

381-10 POWER STEERING GEAR AND PUMP
5. Lock nut
• Remove the adjusting screw lock nut and turn
the adjusting
screw counter-clockwise to
remove the preload between the sector gear
and the rack piston, then remove the
top cover
bolts.
6. Top cover assembly (Fig. 381-15)
• Holding the top cover stationary, turn the
adjusting screw
clockwise to raise and free to
cover, then remove the cover.
Fig. 381-15
7. 0-ring
8. Sector shaft (Fig. 381-16)
• Bring the stub shaft into straight-ahead
position. Do not force the sector shaft
off the
gear
box with a hammer or other impact tools.
9. Ball-nut and valve housing assembly (Fig. 381-
17)
• It is strongly advisable to always keep the ball
nut and valve housing assembly in a horizontal
position, or the rack piston will fall off onto the
end
of the worm, causing the rack piston to slip
out of the worm shaft and the balls to fall out.
10. 0-ring
11. Seal ring
12.
0-ring
13. Gear box
Fig. 381-16
Fig. 381-17
•

(1!] INSPECTION AND REPAIR
Inspect the following parts for wear, damage or any
other abnormal conditions.
• Bearing
• Ball-nut and valve housing
• Sector shaft
• Top cover
• Gear box
• Needle bearing
• Dust seal
• Seal ring
• Gasket
Ball-nut rotation (fig. 381-18)
Hold the ball nut and valve housing assembly vertically
and see
if the ball-nut lowers by turning smoothly. If
the ball-nut does not lower smoothly, check the worm
shaft for bending and foreign matter.
NOTE:
When testing the ball nut and valve housing assembly,
do not let it travel all the way to the end of worm shaft,
or damage to the ball tubes will result.
• Check sector shaft outside diameter (Fig. 381-
19).
~~~ Limit mm (in) 31.7 (1.25)
Fig. 3B1-18
Fig. 3B1-19
POWER STEERING GEAR AND PUMP 381-11
Seal ring setting (fig. 381-20)
8.
~·
Note the setting direction. Always install a
new part.
Apply a thin coat of power steering fluid to lip of
each part.
Dust seal setting (Fig. 381-20)
r=l • Note the setting direction. Always install a
1.=.1 new part.
l<=l()l • Apply a thin coat of power steering fluid to lip of
each part.
Dust seal
Fig. 3B1-20
Gasket setting (fig. 381-21)
1 .. 1• Note the setting direction.
a:;::::;::] • Apply a thin coat of power steering fluid to lip of
D each part.
Fig.
3B1-21

381 -12 POWER STEERING GEAR AND PUMP
l•!+l REASSEMBLY
13. Gear box
12.
0-ring (fig. 381-22)
r:::;:, • Apply a thin coat of power steering fluid.
D • Be sure to discard used part, and always use
new part for installation.
11. Seal ring (fig. 381-22)
r:::;:, • Apply a thin coat of power steering fluid.
D • Be sure to discard used part, and always use
new part for installation.
10.
0-ring (fig. 381-22)
r:::;:, • Apply a thin coat of power steering fluid.
D • Be sure to discard used part, and always use
new part for installation.
Seal ring
Fig. 3B1-22
9.
Ball-nut and valve housing assembly
1) It is strongly advisable to always keep the ball
screw and valve housing assembly in a
horizontal position (avoid holding it
vertically), or the rack piston will fall off onto
the end of the worm, causing the rack piston
to slip out of the worm shaft and ball to fall
out (Fig. 3B1-23).
2) Be careful not to drop the 0-ring into the
valve housing.
3) Tighten the valve housing retaining bolts to
the specified torque.
~~~ Torque N·m (lb.ft) I 47 (35)
8. Sector shaft
1) Tape the sector shaft serrations to protect the
seal ring from damage.
2) Align the center tooth of ball nut with that of
the sector shaft (Fig. 3B1-24). Fig.
3B1-23
Fig. 3B1-24
7. 0-ring
6. Top cover assembly
~~~ Torque N-m (lb·ftl I 47 (35)
5. Lock nut
r:cJ Adjust the backlash between the worm gear and
L:D the ball nut (Fig. 3B1-25).
1) With the worm gear rotating, set it to the
straight ahead position.
2) Set the worm shaft preload to below 1 Okg-cm
with the sector shaft adjusting screw.
3) Measure the worm shaft preload with the
worm gear turned 450° both to the right and
to the left.
The worm gear preload in these positions
should be 2-4kg-cm lower than in the straight
ahead position.
4) Lock the sector shaft adjusting screw with the
lock nut.
~~~ Lock nut torque N-m (lb·ft) I 41 (30)
•