Page 869 of 1395
Power Steering Pump
Replacement
1.Place a suitable container under the vehicle.
Drain the power steering fluid from the reservoir.
Remove the belt by loosening the pump mountingbolt and pump lock bolt.
PUMP MOUNNNG BOI.T24 N.m 12.4 kgt m, 17 lbl.ftl
PUMP LOCK BOLT24 N.m (2.4 kg{.m, 1, tbfttl
Cover the IVC compressor with several shop towelsto protect it from spilled power steering fluid.Disconnect the pump inlet hose and pump outlethose from the pump, and plug them. Take care notto spill the lluid on the body or parts. Wipe off anyspilled fluid at once.
Remove the pump mounting bolt and pump lockbolt, then remove the pump. Do not turn the steer-ing wheelwith the pump removed.
Cover the opening of the pump with a piece of tapeto prevent foreign materialfrom entering the pump.
PUMP OU'I.TT HOSE
11 N.m (1.1 kgf.m,E rbf.ti)
17-24
7.Connect the pump inlet hose and pump outlet hose.Tighten the pump fittings securely.
Loosely install the pump in the pump bracket withthe mounting bolt and lock bolt.
Install the pump belt.
Note these items du.ing belt instsllation:. Make sure that the power steering belt is proper-
ly positioned on the pulleys.
. Do not get power steering fluid or grease on thepower steering belt or pulley faces, Clean off anyfluid or grease before installation
FOWER STEER G EELT
PUTrlY
Adiust the pump belt (see page 17-141.
Fill the reservoir to the upper level line (see page't7 -151..
10.
'l l.
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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 872 of 1395
5. Submerge the valve in a container of power steer-
ing fluid or solvent, and blow in the hose. lf air bub-
bles leak through the valve at less than 98 kPa
(1.0 kgflcm' , 14.2 psi), repair it as follows ('97 model).
For'98 - 00 models, the flow control valve cannot
be disassembled; replace the pump as an assembly
AIR PRESSURE
POWER STEENINGFLUID or SOLVENT
6.For'97 model only, hold the bottom end of the
valve with a open end wrench. Unscrew the seat in
the top end of the valve, and remove any shims, the
reliel check ball, relief valve and relief valve spring.
RELIEFALVE
RELIEF CHECK BALL
{w@r
7.
SEAT9 N.m(0.9 kgf.m, 6.5 lbfft)
RELIEF VALVESPRING
FLOW CONTBOL VALVE
Clean all the parts in solvent, dry them otf, then
reassemble and retest the valve.
The relief pressure is adjusted at the factory by
adding shims under the check ball seat lf you found
shims in your valve, be sure you reinstall as many
as you took out.
lf the flow control valve tests OK, reinstall it in the
pump. It the flow control valve still leaks air, replace
the pump as an assembly. The flow control valve is
not available separately.
8,
Hold this end witha open eno wrencn.
Ball Bearing:
'1. Inspect the ball bearing by rotating the outer race
slowly. lf any play or roughness is felt, replace the
ball bearing.
2. Replace the ball bearing using a press.
Removelnstall
Press
I
Press
I
lnstall with thered shaelded sidefacing down.
NOTEr SuPPort the inner race
with the tool securelY-
BALL EEARING
17-27
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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 877 of 1395
Power Steering Gearbox
AN'USTABLE HOSE CLAMP
Removal (cont'dl
14. Loosen the 14 mm flare
pump outlet hose.
nut, and disconnect the
14 mm FLARE NUT
15. Loosen the adjustable hose clamp and disconnect
the return hose,
16. Loosen the 16 mm flare nut, and remove the return
hose joint.
17. After disconnecting the hoses and lines, plug or seal
them with a piece of tape or equivalent to prevent
foreign maisrials from entering the valve body unit.
NOTE:
. Do not loosen the cylinder line A and B between
the valve body unit and cylinder.
. With 2WD, continue to step 23.
17 -32
STOP BOLT
10 x 1.25 mm
4WD: Stepr 18-22
18. Removethe right tront mount, then apply vinyl tape
to the side frame to protect it from the transmission
cover and stop bolt.
12 x 1.25 fiiAReplace.
RIGHT FRONT MOUNT
x 1,25 mm
SIDE FRAME
'19. Remove the left front mount, then apply vinyl tape
to the side frame to protect it from the stop bolt.
Vinyltape orequivalgnt material.
Vinyltap€ orequival€nt m6terial.
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Page 881 of 1395
Power Steering Gearbox
Disassembly {cont'd}
12. Drill a 3 mm (0.12 in) diameter hole approximately
2.5 - 3.0 mm (0.10 - 0.12 in) in depth in the staked
point on the cylinder. Do not allow metal shavings
to enter the cylinder housing. After removing the
cylinder end, remove any burrs at the staked point.
D.oth: 2.5 - 3.0 mm 10.10 - 0.12 inl
CYUNOER
Hold the gearbox using using a C-clamp as shown,
Loosen and remove the cvlinder end.
13.
17-36
14, Assemble a 12 x 1.25 mm flange nut onto a '12 x 175
mm grade 10 flange bolt as shown, Wrap the flange
portion of the bolt with vinyl tape to protect the
cvlinder,
VINYL TAP€ tp/N 90177 - SLO - OOOI 12mmFLANGENUT
Install the flange bolt into the end of the steering
rack until it bottoms in the hole. then back the
flange bolt out 1/4 turn. Hold the flange bolt, and
tighten the flange nut against the rack by hand.
Install the bearing separator on the gearbox housing
as snown.
15.
BEARING SEPARATOR0 - 1112'(Commercially available)
17.
STEERING RACK
CYLINDER €ND
Set the gearbox in a press so the lelt side points
upward, then press the cylinder end seal and steer-
ing rack out of the gearbox. Hold the steering rack
to keep it from falling when pressed clear. Be care-
ful not damage to inner surface of the cylinder
housing with the flange bolt.
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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 883 of 1395
Power Steering Gearbox
Disassembly (cont'd)
Valve Body Unit Dbassembly
23. Before removing the valve housing, apply vinyltape
to solines of the Dinion shaft.
VALVE HOUSING
Separate the valve housing from the pinion shafv
valve using a press.
Check the inner wall of the valve housing where the
seal ring slides with your finger. lf there is a step in
the wall, the valve housing is worn. Replace the
valve housing.
Note these items during inspection:
o There may be the sliding marks from the seal
ring on the wall of the valve housing. Replace
the valve housing only if the wall is stepped.
. When the valve housing is replaced, install new
shim{s) on the bearing surface of the housing to
adiust the thickness.
Check the inside ofvalve housingfor a step in the wall.
17-38
26. Check for wear, burrs and other damage to the
edges of the grooves in the sleeve.
NOTE: The pinion shaft and sleeve are a precision
matched set. lf either the oinion shaft or sleeve
must be replaced, replace both parts as a set.
SLEEVE SEAL RINGSCheck for Deel off or
27. Remove the circlip and sleeve from the pinion shaft.
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