Page 870 of 1395
Disassembly
Note these items during disassembly:
. The power steering components are made of aluminum, Avoid damaging the components during assembly.
. Clean the disassembled parts with a solvent, and dry them with compressed air. Do not dip the rubber parts in a sol-
vent.
. Always replace the O-rings and rubber seals with new ones before assembly.
. Apply recommended power steering fluid to the parts indicated in the assembly procedures.
. Do not allow dust, dirt, or other foreign materials to enter the power steering system.
. Replace the pump as an assemblyif the parts indicated with asterisk(*) areworn ordamaged.
FLANGE BOLTS20 N.m 12.0 kgt'm,
1a tbf,ft)
.PUMP COVER
ROLLER
PUMP COVER SEAL
*PUMP HOUSING
5l x 2.4 mm O-RINGRepiace.
13 x 1.9 mm O-RINGReplace.
INLET JOINT
*OUTER SIDE PLATE
.PUMP CAM RING
PUMP SEAL SPACER
PUMP DRIVE SHAFT
FLANGE BOLTS11 N.m 11.1 kgt m,8 tbf.ft)
PULI.-EY NUTfl N.m (6.5 kgf.m,/r7 lbf.ftl
(cont'd)
17 -25
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Page 871 of 1395
Power Steering Pump
Disassembly (cont'dl
1.
7.
9.
10.
Drain the fluid from the pump.
Hold the steering pump in a vise with soft jaws.
hold the pulley with the special tool, and remove
the pulley nut and pulley. Be careful not to damagethe pump housing with the jaws of the vise.
UNIVERSAL HOLDER07725 - 0030000
Loosen the flow control valve cap with a hexwrench, and remove it.
Remove the O,ring, flow control valve and spring.
Remove the inlet joint and O-ring.
Remove the pump cover and pump cover seal.
Remove the outer side plate, pump cam ring, pump
rotor, pump vanes, side plate and O-rings.
Remove the snap ring, then remove the sub-valvefrom the pump housing.
Remove the circlip, then remove the pump driveshaft by tapping the shaft end with the ptastic ham-mer.
Remove the pump seal spacer and pump seal.
17-26
Inspection
Flow Control Valve
1. Check the flow control valve for wear, burrs, and
other damage to the edges of the grooves in thevalve.
'97 model:
FLOWCONTROL VALVE
Check fordamage to edges.
'98 - 0O mod€ls:
FLOW CONTBOL VALVE
Check for damageto edges.
Insp€d the bore of the flow control valve tor scratchesor wear.
Slip the valve back in the pump, and check that itmoves in and out smoothly. lf OK, go to step 4; ifnot, replace the pump as an assembly. The flowcontrolvalve is not available separately.
CONTROL VALVE
4. Attach a hose to the end of the valve as shown.
FLOW CONTROL VALVE HOSE
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Page 873 of 1395
Power Steering Pump
Reassembly
'1.Align the pin of the sub-valve with the oil passage
in pump housing, and push down the sub-valve.
Install the snsp ring properly.
OIL PASSAG€Align the pin of
the oil passage.
#q
;1..*
\SNAP RINGPUMP HOUSING
Install the new pump seal (with its grooved side fac-
ing in) into the pump housing by hand, then install
the pump seal spacer.
Position the pump drive shaft in the pump housing,
then drive it in using a 29 mm socket as shown,
BALL BEARfNG grlu,e un.t
/ /ffi\
1 / t\v4
t/ Y
# I F
PUMP SEALSPAC,ER
ry^
i- d
,O mm CIRCLIP
Hgo
/= PUMP DRIVE SHAFT
@.--#$i":*'
4,
PUMP HOUSING
Install the 40 mm circlip with its radiused side fac-
Ing out.
29 mm SOCKET
17 -2A
7.
5. Coat the pump cover seal with power steering fluid,
and install it into the groove in the pump cover.
OUTER SIDE PLATE
5 mrh ROLLER
lnstall the oute. side plate over the two rollers.
PUMP CAM RING
ROLLER SET HOLES
ROLLERS
Set the pump cam ring over the two rollers with the"' " mark on the cam ring upward.
ROLLER SET HOLES
PUMP COVER
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Page 876 of 1395
Power Steering Gearbox
Removal
Note these items during removal:
. Using solvent and a brush, wash any oil and dirt off
the valve body unit its lines, and the end if the gear-
box. Blow dry with compressed air.
. Be sure to remove the steering wheel before discon-
necting the steering joint. Damage to the cable reel
can occur.
. With 4WD. tilt the engine with a jack to expand the
clearance between the transfer assembly and rear
beam when removing the steering gearbox from the
rear oeam.
Do not remove the steering gearbox by removing the
transfer assembly from the transmission.
1. Drain the power steering fluid as described on page'17-15.
Raise the vehicle, and suppon it on safety stands in
the proper locations (see section 1).
Remove the front wheels,
Remove the drive/s airbag assembly {see section 24).
Remove the steering wheel {see page 17-18).
Remove the steering joint bolts, then disconnect the
steering joint by moving the joint toward the column.
UPPER JOINT BOLT
LOWER JOINT BOLT
13.
7. Remove the cotter pin from the nut, and remove the
castle nut {'97 - 98 models) or hex nut ('99 - 00
models).
COTTER PINReplace.
Install the 10 mm hex nut on the ball joint. Be sure
that the 10 mm hex nut is flush with the ball joint
pin end, or the threaded section of the ball joint pin
might be damaged by the special tool. Refer to sec-
tion 18 for ball joint remover usage instruction, Be
careful not to damaging the ball joint boot.
Separate the tie-rod ball joint and knuckle using the
special tool.
Remove the right and left tie-rod ends, then extend
the rack all the way to the right.
Remove the TWC (see section 9).
Disconnect the shift linkage from the transmission
(M/T: see section 13, A/T: see section 14).
With 4WD. separate the propeller shaft and transfer
assembly (see section 161.
10.
11.
(cont'd)
17-31
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Page 882 of 1395
18. Remove the 12 mm bolt and nut trom the stsering
rack,
19. Remove the cylinder end seal from the steering
racK.
20. lnsert a 24" long,3/8" drive extension and the spe-
cial tool into the cvlinder from the left side. Make
sure that the special tool is securely positioned on
the backup ring edges. Be careful not damage to
inner surface of the cylinder with the special tool.
Replace.
I
I
I
CI
24 'LONG 3/8' DRIVE EXTENSION(Commerciallv available)
BACKUP RING
CYLINDER END SEAL
CYLINDER END SEALREMOVER ATTACHMENT07NAD - SR3020A
21.Set the gearbox in a press, then press out the cylin-
der end seal and backup ring from the gearbox.
Note these items when pressing the cylinder end
seat:
. Keep the tool straight to avoid damaging the
cylinder wall. Check the tool angle, and correct it if
necessary, when removing the cylinder end seal.
. Use a press to remove the cylinder end seal. Do
not try to remove the seal by striking the tool. lt
will break the backup ring, and the cylinder end
sealwill remain in the gearbox.
Prass
22. Carelully pry the piston sesl ring and O-ring off the
piston rack. Be careful not to damage the inside of
seal ring groove and piston edges when removing
the seal ring.
Replaco.
(cont'dl
17-37
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Page 888 of 1395
20. Press the new bearing into the valve housing with
the stamped letter facing up using a hydraulic press
and soecialtool.
ATTACHMENT,32x35mm07746 - 0010100
- ROLLER BEARINGLetter stamped face
21. Apply vinyl tape to the pinion shaft, then coat the
vinyltape with power steering fluid.
Sealing lip tace.VALVE OIL SEAL
VALVE HOUSING
SHAFT
SLEEVE SEAL
PINION
E
22, Insert the pinion shaft into the valve housing. Be
careful not to damage the valve seal rings.
23. Remove the vinyl tape from the pinion shaft, then
remove any residue from the tape adhesive.
8e sure that theseal rings are notturned up, theninstall.
DRIVER
24. Press the pinion shaft/sleeve using a hydraulic
press. Check that the pinion shaft/sleeve turns
smoothly by turning the pinion shaft,
(cont'd)
17-43
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Page 900 of 1395
SpecialTools
Ref. No. I Tool Number
o
/a
@/6
lol
o
@6r
@
o
@
@
@
07GAF - SE00l00
07GAG - SD40700
07JAF - SH20200
07LAD - SM40100
07MAC - S100200
07746 - 0010200
07749 - 0010000
07947 - 6340400
07965 - SA50100
07965 - 5400600
07965 - S800100
07965 - S800200
07965 - SD90100
07974 - SA50700
Hub Dis/Assembly Tool
Ball Joint Boot Clip GuideBall Joint Remover Base
Driver Attachment, 60 mm
Ball Joint Remover,23 mmDriver Attachment,3T x 40 mmDriver
Driver Attachment, 62 x 64 mmHub Dis/Assembly Tool
Driver Attachment
Ball Joint Remover/lnstaller
Ball Joint Installer Base
Support Base
Ball Joint Boot Clip Guide
1
1
1
1
1
1
1
1'l
I
1
1
I
1
r 8-'13'18 16
18-15
1A-22
1a-1't,12
1a-21
18-13, 14,21,22
18-13
1a-22
18- 14
18- 15
18-15
l8-14
18-16
c
f1
U
o,o.4.@@,@,@,@
oo@c0
18-2
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Page 910 of 1395
Front Suspension
Knuckle/Hub Replacement (cont'd)
20. Remove the cotter pin from the lower arm ball joint
castle nut, and remove the nut.
COTTER PINReplace.On ra6ssembly,bend the cofter pin
CASTI.E NUT12 x 1.25 mmilg - 59 N.m (5.0 - 6.0 kgf.m, 36 - a3 lbf.ftl
CASTLE NUT12 x 1.25 mm
COITER PINReplace.
BALL JOINT REMOVER, 28 mm07MAC - Sl(xr2(x,
Install a 12 mm hex nut on the ball joint. Make sure
the hex nut is flush with the ball joint pin end, or the
threaded section of the ball joint pin might be dam-
aged by the ball joint remover.
Use the special tool as shown on page 18-11 to sep-
arate the ball joint and lower arm. lf necessary,
apply penetrating type lubricant to loosen the balljoint.
18-12
23. Remove the cotter pin from the upper ball joint cas-
tle nut, and remove the nut.
COTTER PINReplace.On reassembly, bendthe cotter pin as shown.
CASTLE NUT10 x 1.25 mm39 - 47 N.m14.0 - ,4.8 kgt m,29 - 35 tbt.ftl
24.
25.
26.
10 mmnEMOVER, 28 mm07MAC _ SLtD2(xl
Install the 10 mm hex nut on the ball joint.
Make sure the hex nut is flush with the ball joint pin
end, or the threaded section of the ball joint pin
might be damaged by the ball joint remover.
Use the special tool as shown on page 18-11 to sep-
arate the ball joint and knuckle. lf necessary, apply
penetrating type lubricant to loosen the ball joint.
Pull the knuckle outward, and remove the driveshaft
outboard joint from the knuckle by tapping the driv+
shaft end with a pl8stic hammer, then remove the
knuckle.
KNUCKI.ECheck lor damage.
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