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STEERING COLUMN
PS-9
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STEERING COLUMNPFP:48810
Removal and InstallationEGS00094
CAUTION:
Care must be taken not to give axial impact to steering column assembly during removal and installa-
tion.
REMOVAL OF LOWER JOINT AND HOLE COVER
1. Raise vehicle with front wheels in straight-ahead position.
2. Mark lower joint and steering gear with paint for easy installation. Remove pinch bolt from lower side of
lower joint.
3. Remove mounting bolt and nut from upper side of lower joint.
4. Remove footrest.
5. Remove hole cover and lower joint from vehicle.
6. Remove clamp and lower seal cover from hole cover.
INSTALLATION OF LOWER JOINT AND HOLE COVER
lRefer to component diagram for tightening torque. Install in the reverse order of removal.
lConnect lower joint onto steering gear with slot on lower portion of lower joint engaged with guide tip pro-
jection. Check guide tip is positioned as shown in the figure.
REMOVAL OF STEERING COLUMN ASSEMBLY
1. Remove steering wheel and column cover. Refer toPS-7, "REMOVAL".
2. Remove the instrument of the driver-side lower panel.
3. Remove spiral cable. Refer toSRS-31, "
REMOVAL".
4. Remove lower cover and mounting bolts and nuts on upper portion of lower joint.
SGIA0015E
1 Steering column assembly 2 Hole cover 3 Lower joint
4 Steering wheel 5 Air bag module 6 Spiral cable
7 Column cover
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PS-10
STEERING COLUMN
5. Remove the key interlock cable from the steering column assembly. Refer toAT- 4 5 2 , "Removal".
6. Remove clamp and connector from steering column assembly.
7. Remove steering column assembly mounting nut and remove steering column assembly from vehicle.
CAUTION:
Do not deform lower bracket on steering column assembly during removal or installation.
INSTALLING STEERING COLUMN ASSEMBLY
lInstallation procedure should be used with steering lock unlocked.
1. Position on steering column assembly, and install steering column assembly to vehicle with mounting
nuts.
2. Attach mounting bolts and nuts on upper portion of lower joint.
CAUTION:
Do not reuse mounting nuts.
3. Connect clamp and connector.
4. Connect key interlock cable to steering column assembly. Refer toAT-453, "
Installation"
5. Connect spiral cable. Refer toSRS-32, "INSTALLATION".
6. Install instrument lower driver panel.
7. Install steering wheel and column cover. Refer toPS-7, "
INSTALLATION".
CAUTION:
After installation, turn steering wheel. Be sure it turns smoothly with no disinterred condition,
binding, noise or excessive steering effort.
Disassembly and AssemblyEGS00095
DISASSEMBLY
lDisassembly and assembly procedures should be done with steering lock unlocked.
1. Remove combination switch from jacket tube.
2. Remove jacket tube-to-column shaft mounting nut and remove column shaft from jacket tube.
3. Remove spring from mount assembly.
4. Remove mounting nut and adjusting stopper.
5. Remove steering adjusting bolt and remove tilt lever stopper and tilt lever.
SGIA0016E
1 Column shaft 2 Clip 3 Lower seal cover
4 Hole cover 5 Combination switch 6 Jacket tube
7 Mount assembly 8 Adjust stopper 9 Steering adjust bolt
10 Spring 11 Tilt lever stopper 12 Tilt lever
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STEERING COLUMN
PS-11
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INSPECTION AFTER DISASSEMBLY.
lIf steering wheel does not turn smoothly, check the following and replace malfunctioning part.
1. Check column shaft bearing for damage and other malfunctions. Lubricate with grease or replace column
shaft if necessary.
2. Check jacket tube for deformation and cracks, and replace if necessary.
lIf vehicle has slightly crashed, measure dimension L as shown.
If outside standard, replace steering column assembly.
ASSEMBLY
lRefer to component parts drawing for tightening torque and reverse disassembly procedure for assembly.
lAfter assembling steering column, check tilt mechanism.Dimension L : 543 mm (21.38 in)
STC0720D
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PS-12
POWER STEERING GEAR AND LINKAGE
POWER STEERING GEAR AND LINKAGE
PFP:49001
Removal and InstallationEGS0004I
REMOVAL
1. Remove cotter pin, and loosen mounting nut. Remove tie rod from steering knuckle with a pitman arm
puller.
CAUTION:
lBe careful not to damage dust boot at ball joint of tie rod.
lBefore using pitman arm puller (multi-purpose tool), loosely tighten nut for temporary holding.
2. Mark lower joint and steering gear with paint for easy installation. Remove pinch bolt from gear side of
lower joint.
3. Remove high pressure-side tube and low pressure-side hose of hydraulic piping from steering gear.
4. Remove mounting nuts on upper portion of stabilizer connecting rod and stabilizer clamp mounting bolts.
Move stabilizer toward vehicle front.
5. Remove steering gear assembly mounting bolts and nuts. Remove power steering tube bracket and
steering gear assembly from suspension member.
6. Tilt steering gear to prevent any contact with other parts. Then remove it from right side of vehicle.
INSTALLATION
Paying attention to following items, install in the reverse order of removal.
lAfter installation, bleed air. Refer toPS-5, "Bleeding Hydraulic System".
lRemove mounting bolt and nut from upper portion of lower joint. This will facilitate installation of lower joint
to steering gear. Then slide lower joint in place.
lCheck lower slit of lower joint is engaged with projection on rear
cover cap. Install pinch bolt for lower portion of lower joint.
Check steering gear is in straight-ahead position. Also check
rear cover is in position shown in figure. Then install lower joint
to steering gear.
SGIA0009E
1 Power steering gear assembly 2 Power steering tube bracket 3 Cotter pin
SGIA0105E
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POWER STEERING GEAR AND LINKAGE
PS-13
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SGIA0010E
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PS-14
POWER STEERING GEAR AND LINKAGE
Components
EGS0004J
MODEL PR24AD
SGIA0011E
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POWER STEERING GEAR AND LINKAGE
PS-15
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Disassembly and AssemblyEGS0004K
DISASSEMBLY
1. To disassemble and assemble power steering gear, fix steering
gear mount flange in a vise with copper plates.
CAUTION:
lClean steering gear with kerosene. Be careful to avoid
splashing or applying any kerosene over connector of
discharge port or return port.
lAlways replace O-rings, oil seals, and copper washes
with new ones.
2. Loosen and remove adjusting screws and lock nuts.
3. Remove rear housing mounting bolts to remove gear sub
assembly.
CAUTION:
Do not disassemble rear housing and pinion gear assem-
bly.
4. Remove tie rod outer socket and boot.
5. Remove spacer ring on lock plate. Move it to rack side to expose
crimping of lock plate.
CAUTION:
lDo not reuse boot, spacer ring, and lock plate.
lWhen removing boot, do not damage boot mounting
grooves by tool. If it damaged, it may cause oil leak.
Replace tie rod inner socket and gear housing assembly.
lWhen removing lock plate from rack, avoid damaging
surface of rack. If damaged, rack assembly must be
replaced. Otherwise, oil leaks will result.
6. Raise crimping areas (2) (A) of lock plate. Loosen inner socket and remove from rack.
1 Gear housing assembly 2 Cylinder tube 3 Rear cover cap
4 Rear housing assembly 5 Pinion seal ring 6 Pinion assembly
7 O ring 8 Lock nut 9 Adjusting screw
10 Spring 11 Retainer 12 Center bushing
13 Rack oil seal (inner) 14 Rack oil seal (outer) 15 Spacer
16 End cover assembly 17 Boot clamp 18 Dust boot
19 Boot band 20 Rack 21 Spacer ring
22 Rack seal ring 23 O-ring 24 Lock plate
25 Inner socket 26 Outer socket
SGIA0056E
SGIA0018E
SGIA0019E
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PS-16
POWER STEERING GEAR AND LINKAGE
7. Drill out punch crimping area on cylinder outer rim with a 3-mm
(0.12in) drill bit.{Drill for approx. 1.5 mm (0.059in) in depth.}
8. Remove end cover with a 36-mm (1.42 in) open head.
CAUTION:
When removing, avoid damaging surface of rack. If dam-
aged, rack assembly must be replaced. Otherwise, oil leaks
will result.
9. Pull rack assembly with rack seal out of gear housing assembly.
CAUTION:
When pulling out rack assembly, do not damage cylinder
inner wall. If it damaged, it may cause oil leak. Replace gear
housing assembly.
10. Heat Teflon ring to approx. 40°C (104°F) with a hot air blower Remove it and O-ring from rack. Be careful
not to damage rack.
11. Use a taped 29-mm socket and an extension bar. Push out and
remove center bushing and rack oil seal together from pinion
housing.
CAUTION:
lBe careful not to damage pinion housing and cylinder
inner wall.
lIf damaged, gear housing assembly must be replaced.
Otherwise, oil leaks will result.
PINION GEAR ROTATION TORQUE ADJUSTMENT
INSPECTION AFTER DISASSEMBLY
Boot
Check boot for tear, wrinkle, and deformation. Replace it, if necessary.
Rack
Check rack gear for damage and wear. Replace it, if necessary.
Gear subassembly
lCheck pinion gear for damage and wear, and replace if necessary.
lCheck bearing while rotating it. Replace bearing if bearing ball race was dent, worn, or damaged.
Gear housing cylinder
Check gear housing cylinder for damage and scratch (inner wall). Replace it, if necessary.
Tie rod ball joint
1. Tensile force
STC0013D
SST052C
SST472A