Page 905 of 2453

PS-25
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
5) Install the ST on rack, equally apply a thin coat of
grease to the rack and ST, and then install the oil
seal.
ST 926250000 GUIDE
CAUTION:
Be careful not to scratch the oil seal lips with
the inner ring section of piston.
6) Apply a coat of grease to the grooves in rack,
sliding surface of sleeve and sealing surface of pis-
ton. Then insert the rack into steering body from
cylinder side.
7) Check the threaded end of holder and gearbox
cylinder end for burrs, damage, etc. Correct if
faulty.
8) Insert the ST into gearbox cylinder, and then
press-fit the oil seal.
ST 34199XA000 INSTALLER 44
9) Temporarily tighten the holder to gearbox cylin-
der.
10) Set the ST to the end of rack.
ST 34199XA030 INSTALLER & REMOVER 44
11) Using a press, press-fit until the groove of ST
are aligned to the end surface of holder.
12) Secure the gearbox in a vise using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
13) Tighten the holder.
Tightening torque:
85 N·m (8.7 kgf-m, 62.7 ft-lb)
(1) Rack piston inner ring
(2) Outer side oil seal
(3) Rack
PS-00078
PS-00521
ST
(1) Groove
(2) Holder
(1) Clamp
(1) Holder
PS-00522
ST
(1)
(2)
PS-00492
(1)
ST1
ST2
PS-00512
(1)
Page 906 of 2453

PS-26
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
14) Using the ST, caulk so that the diameter of
punch hole is 2 — 2.5 mm (0.08 — 0.10 in) and is
aligned to the position of 2 mm (0.08 in) from gear-
box cylinder end surface.
ST 34099FA060 PUNCH HOLDER
15) Put a vinyl tape around the spline portion and
apply genuine grease to the dust cover and install
to valve assembly.
CAUTION:
Be sure to install the dust cover to groove of
shaft.
16) Apply the genuine grease to the pinion gear
and bearing of valve assembly.
17) Install a new gasket on valve assembly. Insert
the valve assembly into place while facing the rack
teeth toward pinion.
18) Tighten the bolts alternately to secure the valve
assembly.
Tightening torque:
20 N·m (2.0 kgf-m, 14.8 ft-lb)
CAUTION:
Be sure to alternately tighten the bolts.
19) Temporarily install the tie-rod to rack end, and
then operate the rack from lock to lock for two or
three times to make it fit in. Remove any grease
blocking the air vent hole.
CAUTION:
Operating the rack from lock to lock without in-
stalling tierods may damage the oil seal. Al-
ways install the LEFT AND RIGHT tierods.
20) Apply liquid gasket to more than 1/3 of entire
perimeter of adjusting screw thread.
Liquid gasket:
THREE BOND 1141
21) Apply a coat of grease to the sliding surface of
sleeve and seating surface of spring, and then in-
sert the sleeve into steering body.
Charge the adjusting screw with grease, and then
insert the spring into adjusting screw. Then install
on the steering body.
(1) 2 mm (0.08 in)
(2) Diameter: 2 — 2.5 mm (0.08 — 0.10 in)
(3) End of cylinder
(4) Holder
(1) Dust cover
(2) Groove
PS-00523
(1)
(2)(4)
(3)
PS-00534
(1)
(2)
PS-00165
(1) Sleeve
(2) Spring
(3) Adjusting screw
PS-00117
PS-00167
(2)
(1)
(3)
Page 907 of 2453

PS-27
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
22) Tighten the adjusting screw to the specified
torque.
Tightening torque:
3.9 N·m (0.4 kgf-m, 2.9 ft-lb)
23) Tighten the adjusting screw to the specified
torque, then loosen it 20°.
24) Remove the tie–rod.
25) Adjust the turning resistance of gearbox so that
it is within specification using adjusting screw.
GEARBOX, INSPECTION, Steering Gearbox.>
26) Apply liquid gasket to lock nut and install it into
adjusting screw. While holding the adjusting screw
with wrench, tighten the lock nut using ST.
Liquid gasket:
THREE BOND 1141
ST 926230000 SPANNER
Tightening torque (lock nut):
25 N·m (2.5 kgf-m, 18.1 ft-lb)
NOTE:
Hold the adjusting screw with a wrench to prevent it
from turning while tightening lock nut.
27) Extend the rack approx. 40 mm (1.57 in) from
steering body.
28) Install the tie-rod and new lock washer into
rack.
Tightening torque:
130 N·m (13.3 kgf-m, 95.9 ft-lb)
29) Bend the lock washer and caulk it.
CAUTION:
Be careful not to scratch the rack when caulk-
ing lock washer.
30) Apply a coat of grease to the tie–rod groove,
and then install the boot to the housing.
CAUTION:
Right side boot has groove for identification, be
sure to install the right and left of boot.
(1) Lock washer
(2) Approx. 40 mm (1.57 in)
PS-00439
(2)
(1)
(1) Lock washer
(1) Right side boot
(2) Groove for identification
PS-00093
PS-00524
(2)
(1)
Page 908 of 2453

PS-28
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
NOTE:
Make sure that the boot is installed without unusual
inflation or deflation.
31) Install a new boot band. Using band clamp pli-
ers, caulk it so that the clearance of caulking por-
tion becomes 2mm (0. 079 in) or less.
32) Fix the boot end with small clip.
33) After installing, check that the boot end is in-
stalled to the groove of the tie–rod.
34) If the tie-rod end has been removed, screw in
lock nut and tie-rod end to the screwed portion of
tie–rod, and tighten the lock nut temporarily in a po-
sition as shown in the figure.
Installed tie-rod length L:
31 mm (1.22 in)
35) Inspect the gearbox as follows:
Holding the “A” tie–rod end, repeat movement from
lock to lock two or three times as quickly as possi-
ble.
Holding the “B” tie–rod end, turn a few times as
slowly as possible.
Finally, make sure that the boot is installed in the
specified position without inflating.
36) Remove the gearbox from ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
(A) Boot band
(B) Less than 2 mm (0.079 in)
PS-00194
PS-00499
(A)
(B)
(1) Clip
PS-00053
PS-00097
L
PS-00098
BA
Page 909 of 2453

PS-29
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
37) Install the four pipes on gearbox.
(1) Connect the pipes A and B to the four pipe
joints of gearbox.
Tightening torque:
Refer to the component parts.
POWER ASSISTED SYSTEM, COMPONENT,
General Description.>
(2) Connect the pipes C and D to gearbox.
Tightening torque:
Pipe C: 37 N·m (3.8 kgf -m, 27.3 ft-lb)
Pipe D: 29 N·m (3.0 kgf-m, 21.4 ft-lb)
2. CONTROL VALVE ASSEMBLY
Specified steering grease:
VALIANT GREASE M2 (Part No. 003608001)
1) Clean all parts and tools before reassembling.
2) Apply a coat of specified power steering fluid to
the inner wall of valve housing.
3) To avoid scratching the oil seal, apply a coat of
grease to the contact surface of installer and oil
seal.
4) Verify the direction of oil seal. Install the oil seal
to installer and position it to valve housing.
5) Press the oil seal into position using press.
ST 34199AG090 INSTALLER & REMOVER
6) Install the bearing to ST and position it to hous-
ing. Using the ST and a press, install the special
bearing in valve housing.
ST 34199AG090 INSTALLER & REMOVER
7) Apply vinyl tape to the groove of pinion.
(1) Pipe C
(2) Pipe D
(1) Apply fluid.
PS-00525(1)
(2)
PS-00169(1)
(1) Special bearing
(2) Oil seal
PS-00526
ST
(2)
(1)
PS-00527
ST
Page 910 of 2453
PS-30
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
8) Install the back-up ring and oil seal to pinion, and
then remove the vinyl tape.
9) Install the ST to pinion, and install the seal ring.
ST 34199AG020 GUIDE
10) Remove the ST GUIDE, and form the seal ring
properly using ST FORMER.
ST 34199AG070 FORMER
11) Put vinyl tape around pinion shaft spline to pro-
tect oil seal from damage.
12) Install the valve to pinion, and install the snap
ring.
13) Attach the pinion & valve assembly into the
valve housing.
14) Using a press, push the outer race of bearing
and press-fit the pinion & valve assembly into hous-
ing.
15) Apply the specified grease to dust cover.
(1) Oil seal
(2) Vinyl tape
(3) Back–up ring
(1) Seal ring
(1) Seal ring
PS-00528
(1)
(2)(3)
PS-00529
(1)
ST
PS-00530
ST
(1)
(1) Snap ring
(2) Valve
(1) Valve housing
(2) Pinion & valve ASSY
(1) Pinion & valve ASSY
(2) Bearing
(3) Housing
PS-00531
(2)
(1)
PS-00532(1)
(2)
PS-00533
(1)
(2)
(3)
Page 911 of 2453

PS-31
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
16) Install the dust cover on valve assembly.
CAUTION:
Be sure to install the dust cover to groove of
shaft.
17) Apply the genuine grease to the pinion gear
and bearing of valve assembly.
18) Install new O-ring to valve assembly.
19) Insert the valve assembly into place while fac-
ing the rack teeth toward pinion.
20) Tighten the bolts alternately to secure the valve
assembly.
Tightening torque:
20 N·m (2.0 kgf-m, 14.8 ft-lb)
CAUTION:
Be sure to alternately tighten the bolts.
21) Apply liquid gasket to more than 1/3 of entire
perimeter of adjusting screw thread.
Liquid gasket:
THREE BOND 1141 (Part No. 004403006)
22) Apply a coat of grease to the sliding surface of
sleeve and seating surface of spring, and then in-
sert the sleeve into steering body.
Charge the adjusting screw with grease, and then
insert the spring into adjusting screw. Then install
on the steering body.
23) Tighten the adjusting screw to the specified
torque.
Tightening torque:
3.9 N·m (0.4 kgf-m, 2.9 ft-lb)
24) Tighten the adjusting screw to the specified
torque, then loosen it 20°.
(1) Dust cover
(2) Groove
(1) O–ring
PS-00534
(1)
(2)
PS-00165
PS-00535
(1)
(1) Sleeve
(2) Spring
(3) Adjusting screw
PS-00143
PS-00167
(2)
(1)
(3)
Page 912 of 2453

PS-32
Steering Gearbox
POWER ASSISTED SYSTEM (POWER STEERING)
25) Adjust the turning resistance of gearbox so that
it is within specification using adjusting screw.
GEARBOX, INSPECTION, Steering Gearbox.>
26) Apply liquid gasket to lock nut and install it into
adjusting screw. While holding the adjusting screw
with wrench, tighten the lock nut using ST.
Liquid gasket:
THREE BOND 1141
ST 926230000 SPANNER
Tightening torque (lock nut):
25 N·m (2.5 kgf-m, 18.1 ft-lb)
NOTE:
Hold the adjusting screw with a wrench to prevent it
from turning while tightening lock nut.
27) Remove the gearbox from ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
28) Install the four pipes on gearbox.
(1) Connect the pipes A and B to gearbox.
Tightening torque:
Refer to the component parts.
POWER ASSISTED SYSTEM, COMPONENT,
General Description.>
(2) Connect the pipes C and D to gearbox.
Tightening torque:
Pipe C: 37 N·m (3.8 kgf -m, 27.3 ft-lb)
Pipe D: 29 N·m (3.0 kgf-m, 21.4 ft-lb)
(1) Pipe C
(2) Pipe D
PS-00525(1)
(2)