Page 1175 of 1226

Bleeding Hydraulic System
1. Raise front end of vehicle until wheels are clear of the ground.
2. Add ¯uid into oil tank to speci®ed level. Then, quickly turn steer-
ing wheel fully to right and left and lightly touch steering stop-
pers.
Repeat steering wheel operation until ¯uid level no longer
decreases.
3. Start engine.
Repeat step 2 above.
+Incomplete air bleeding will cause the following to occur. When
this happens, bleed air again.
a. Air bubbles in reservoir tank
b. Clicking noise in oil pump
c. Excessive buzzing in oil pump
Fluid noise may occur in the valve or oil pump. This is common
when the vehicle is stationary or while turning steering wheel
slowly. This does not affect performance or durability of the system.
Checking Steering Wheel Turning Force
1. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Bring power steering ¯uid up to adequate operating tempera-
ture. [Make sure temperature of ¯uid is approximately 60 to
80ÉC (140 to 176ÉF).]
Tires need to be in¯ated to normal pressure.
4. Check steering wheel turning force when steering wheel has
been turned 360É from the neutral position.
Steering wheel turning force:
39 N (4 kg, 9 lb) or less
Checking Hydraulic System
Before starting, check belt tension, driving pulley and tire pressure.
1. Set Tool. Open shut-off valve. Then bleed air. Refer to ``Bleed-
ing Hydraulic System'', ST-6.
2. Run engine at idle speed or 1,000 rpm.
Make sure ¯uid temperature in reservoir tank rises to 60 to
80ÉC (140 to 176ÉF).
WARNING:
Warm up engine with shut-off valve fully opened. If engine is
started with shut-off valve closed, ¯uid pressure in the power
steering pump increases to maximum. This will raise ¯uid tem-
perature abnormally.
3. Check pressure with steering wheel fully turned to left and right
positions with engine idling at 1,000 rpm.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
Power steering pump maximum operating pressure:
8,140 - 8,728 kPa (81.4 - 87.3 bar, 83 - 89 kg/cm
2,
1,180 - 1,266 psi)
+If pressure reaches maximum operating pressure, system is
OK.
+If pressure increases above maximum operating pressure,
check power steering pump ¯ow control valve. Refer to ST-16.
SST491B
SST834-E
ON-VEHICLE SERVICE
ST-6
Page 1179 of 1226
Disassembly and Assembly
V1Combination switch
V2Lock nut
V3Jacket tube assembly
V4Tilt lever
V5Tilt spring
V6Steering column shaft assembly
V7Band
V8Column cover
V9Coupling
+When disassembling and assembling, unlock steering lock with
key.
+Install lock nut on steering column shaft and tighten the nut to
speci®cation.
: 25-34Nzm (2.5 - 3.5 kg-m, 18 - 25 ft-lb)
+Steering lock
a. Break self-shear type screws with a drill or other appropriate
tool.
b. Install new self-shear type screws and then cut off self-shear
type screw heads.
SST760C
SST490C
SST742A
STEERING WHEEL AND STEERING COLUMN
ST-10
Page 1182 of 1226
Removal and Installation
Before removal, clean gear housing and oil pump exteriors
using a steam cleaner. Then dry with compressed air.
+Plug openings of gear housing, and securely locate hose con-
nectors at a position higher than oil pump and cover with paper
towels.
+Be extremely careful to prevent entry of foreign matter into
hoses through connectors.
+When installing pitman arm, align four grooves of pitman arm
serrations with four projections of sector shaft serrations, and
install and tighten lock washer and nut.
Inspection
Do not disassemble for power steering gear assembly.
TURNING TORQUE MEASUREMENT
1. Measure turning torque at 360É position.
a. Install steering gear on Tool.
SST774C
SST040-A
POWER STEERING GEAR (Model: PB69K)
ST-13
Page 1183 of 1226
b. Turn stub shaft all the way to right and left several times.
c. Measure turning torque at 360É position from straight-ahead
position with Tools.
Turning torque at 360É
0.15 - 0.78 Nzm (1.5 - 8.0 kg-cm, 1.3 - 6.9 in-lb)
2. Measure turning torque at straight-ahead position.
Straight-ahead position is a position where stub shaft is
turned 2.14 turns (two full turns and 50É) from lock position.
Turning torque at straight-ahead position:
0.2 - 0.5 Nzm (2 - 5 kg-cm, 1.7 - 4.3 in-lb)
higher than turning torque at 360É
Maximum turning torque:
0.44 - 1.18 Nzm (4.5 - 12 kg-cm, 3.9 - 10.4 in-lb)
3. Check sector shaft end play in neutral position.
End play:
Less than 0.1 mm (0.004 in)
If turning torque and end play are not within speci®cations,
replace power steering gear assembly.
SST652AA
POWER STEERING GEAR (Model: PB69K)
Inspection (Cont'd)
ST-14
Page 1191 of 1226
General Speci®cations
Power steering
Steering gear type PB69K
Turns of steering wheel on the vehicle
(Lock-to-lock)3.4
Steering gear ratio 17.0Steering wheel axial play
mm (in)0 (0)
Steering wheel play
mm (in)35 (1.38) or less
Steering damper
[at 0.3 m (1.0 ft)/sec.]
N (kg, lb)4,443 (453, 999) ...
Extended direction
3,315 (338, 745) ...
Compressed direction
Inspection and Adjustment
STEERING COLUMN
Unit: mm (in)
Steering column (L1) 679.9 - 681.5 (26.77 - 26.83)
Steering column lower shaft (L
2) 489.3 - 493.3 (19.26 - 19.42)
STEERING LINKAGE
Tie-rod & drag link ball joint
Swinging force at cotter pin hole N (kg, lb)4.9 - 49.0
(0.5 - 5.0, 1.1 - 11.0)
Rotating torque
Nzm (kg-cm, in-lb)0.3 - 2.9
(3 - 30, 2.6 - 26.0)
Axial end play mm (in) 0 (0)
Tie-rod standard length (L)
mm (in)1,302 (51.26)
Drag link standard length (L)
mm (in)1,123.4 (44.23)
SST761C
SST768C
SST769C
SERVICE DATA AND SPECIFICATIONS (SDS)
ST-22
Page 1219 of 1226
AIR BREATHER
+Install as shown in illustration.
Thread locker:
Refer to TF-10.
Shift Control Components
INSPECTION
+Check contact surface and sliding surface for wear, scratches,
projections or other faulty conditions.
L & H SHIFT ROD & FORK
+Assemble as shown in illustration.
* This pin is the same size as the one for 2-4 shift rod.
2-4 SHIFT ROD & FORK
+Assemble as shown in illustration.
* These pins are the same size.
+Pay attention to the direction of fork guide collar.
SMT148B
SMT360A
SMT149B
SMT150B
SMT033B
REPAIR FOR COMPONENT PARTS
TF-26
Page 1221 of 1226
e. Insert interlock plunger into front case.
f. Install L & H shift rod and fork assembly with coupling sleeve.
g. Install 2-4 shift rod.
h. Install switches, check balls, check springs and plugs.
+Apply sealant to switches and plugs.
3. Select counter gear rear bearing shim.
Counter gear end play:
0 - 0.2 mm (0 - 0.008 in)
a. Measure distance ``A'' between upper surface of counter gear
rear bearing and mating surface of front case.
SMT090B
SMT155B
SMT265D
SMT259D
SMT335A
ASSEMBLY
TF-28