23 2005 2006 toyota hilux factory service manual steering column system he thong lai

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REPAIR

(a) Inspect steering wheel off center

(1) Apply masking tape to the top center of the steering wheel and steering column upper cover

(2) Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph (56 km/

h), and hold the steering wheel to maintain the course

(3) Draw a line on the masking tape as shown in the illustration

(4) Turn the steering wheel to its straight position

HINT:

Refer to the steering column upper cover and marked line on the steering wheel for the straight position

(5) Draw a new line on the masking tape or the steering wheel as shown in the illustration

(6) Measure the distance between the 2 lines on the masking tape of the steering wheel

(7) Convert the measured distance to the steering angle

Measured distance 1 mm (0.04 in.):

Steering angle approximately 1 deg.

(b) Adjust the steering angle

(1) Draw a line on the RH and LH tie rods and on the RH and LH rack ends which can easily be seen

(2) Using a paper gauge, measure the distance from RH and LH tie rod ends to the rack end screws

HINT:

(3) Remove the RH and LH boot clips from the rack boots

(4) Loosen the RH and LH lock nuts

(5) Turn the RH and LH rack ends by the same amount (but in different directions) according to the steering angle

Amount of turn:

horizontal movement) - 12 ° of steering

angle.

(6) Tighten the RH and LH lock nuts

Torque: 55.5 N*m (566 kgf*cm, 41 ft.*lbf) NOTICE:

Make sure that the difference in length between the RH and LH tie rod ends and rack end screws is less than 1.5 mm (0.059 in.).

(7) Install the RH and LH boot clips

Marked Line

R000429E06

F016018E02

REMOVAL

TERMINAL

NO 1 (for 4WD and Pre-Runner)

EM-5 )

1

(a) Disengage the clip and disconnect the oil reservoir

to pump hose No 1

(a) Remove the union bolt, then disconnect the pressure feed tube

(b) Remove the gasket from the pressure feed tube

(a) Disconnect the oil pressure switch connector

(b) Remove the bolt and wire harness clamp bracket

(c) Remove the 2 bolts and vane pump assembly

F051257

F051258

F051259

DISASSEMBLY

(a) Using SST, fix the vane pump assembly in a vise

NOTICE:

When using a vise, do not over tighten it.

(a) Remove the bolt and suction port union

(b) Remove the O-ring from the suction port union

(a) Remove the pressure port union

(b) Remove the O-ring from the pressure port union.(c) Remove the flow control valve and compression spring

SWITCH NOTICE:

Be careful not to drop or badly damage the oil pressure switch If damaged, replace it with a new one.

(a) Remove the 4 bolts and vane pump housing rear from the vane pump housing front

(b) Remove the O-ring from the vane pump housing front

(b) Remove the pulley shaft

(a) Remove the 10 vane plates

(b) Remove the vane pump rotor

(a) Remove the side plate from the vane pump housing front

(b) Remove the O-ring from the side plate

SST

F042477E01

(c) Remove the O-ring from the vane pump housing front

10 REMOVE VANE PUMP HOUSING OIL SEAL

(a) Using screwdriver, remove the oil seal

NOTICE:

Be careful not to damage the vane pump housing front.

INSPECTION

(a) Using a micrometer and caliper gauge, measure the oil seal clearance

Standard clearance:

0.021 to 0.043 mm (0.0008 to 0.0017 in.) Maximum clearance:

1.408 mm (0.0554 in.) Minimum length:

11.993 mm (0.4722 in.)

(b) Using a feeler gauge, measure the clearance between a side face of the vane pump rotor groove and vane plate

Length

N000372E03

Feeler Gauge

(a) Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole under its own weight

(b) Check the flow control valve for leakage Close one

of the holes and apply compressed air of 392 to 490

opposite side Confirm that the air does not flow out

of the end holes

If necessary, replace the vane pump assembly

(a) Using vernier calipers, measure the free length of the spring

Minimum free length:

36.9 mm (1.453 in.)

If it is not within the specification, replace the vane pump assembly

(a) If the union seat in the pressure port union is badly damaged, it could cause fluid leakage, so replace the vane pump assembly

PARTS LOCATION

ECM

IGNITION SWITCH AIR CONDITIONER AMPLIFIER ASSEMBLY

AIR CONDITIONING CONTROL ASSEMBLY

BLOWER RESISTOR

COOLER EVAPORATOR SUB-ASSEMBLY

HEATER RADIATOR UNIT ASSEMBLY

AIR INLET CONTROL SERVOMOTOR

NO 1 EXPANSION VALVE

COOLER THERMISTOR SENSOR

AIR FILTER

BLOWER WITH FAN MOTOR SUB-ASSEMBLY

MODE CONTROL SERVOMOTOR AIR MIX CONTROL

SERVOMOTOR

(a) Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the steering wheel cover lower No 2.

(a) Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the

No 3 lower steering wheel cover

(a) Remove the steering wheel assembly set nut

(b) Place matchmarks on the steering wheel assembly and main shaft assembly

(c) Using SST, remove the steering wheel assembly

SST 09950-50013 (09951-05010, 09952-05010,

09953-05020, 09954-05021)

(a) Remove the 2 screws

(b) Disengage the 2 claws to remove the lower steering column cover

(a) Disengage the claw and then remove the upper steering column cover

10 REMOVE SPIRAL CABLE SUB-ASSEMBLY (See page

RS-566 )

11 REMOVE WINDSHIELD WIPER SWITCH ASSEMBLY (See page WW-17 )

13 REMOVE FRONT DOOR SCUFF PLATE LH (for Regular Cab) (See page IR-40 )

14 REMOVE FRONT DOOR SCUFF PLATE LH (for Access Cab) (See page IR-61 )

15 REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab) (See page IR-12 )

16 REMOVE COWL SIDE TRIM BOARD LH (for Regular Cab) (See page IR-40 )

17 REMOVE COWL SIDE TRIM BOARD LH (for Access Cab) (See page IR-61 )

18 REMOVE COWL SIDE TRIM BOARD LH (for Double Cab) (See page IR-12 )

19 REMOVE INSTRUMENT PANEL UNDER TRAY (for Pedal Type Parking Brake) (See page IP-9 )

20 REMOVE INSTRUMENT PANEL HOLE COVER (for Lever Type Parking Brake) (See page IP-9 )

21 REMOVE INSTRUMENT PANEL LOWER LH (See page IP-14 )

22 REMOVE INSTRUMENT PANEL COVER

23 REMOVE STEERING COLUMN HOLE COVER

(a) Disengage the 4 clips and remove the steering column hole cover

24 REMOVE NO 1 ENGINE UNDER COVER ASSEMBLY

SUB-(a) Remove the No 1 engine under cover assembly with the 4 bolts

sub-F051319E01

F051329

25 REMOVE NO 2 STEERING INTERMEDIATE SHAFT

(a) Mark matchmarks on the power steering gear assembly and No 2 steering intermediate shaft

(b) Remove bolt C and No 2 steering intermediate shaft from the power steering gear assembly

26 REMOVE STEERING SLIDING YOKE

(a) Mark matchmarks on the steering sliding yoke, steering intermediate shaft sub-assembly No 2 and steering intermediate shaft assembly

(b) Remove bolts A and B from the steering sliding yoke

(c) Slide the steering sliding yoke up and separate it from the steering intermediate shaft sub-assembly

No 2

(d) Pull down the steering sliding yoke from the steering intermediate shaft assembly to remove

27 REMOVE STEERING COLUMN ASSEMBLY

(a) Disconnect the connectors and wire harness clamps

(b) Remove the bolt and 2 nuts, then remove the steering column assembly from the instrument panel reinforcement assembly

(a) Remove the tilt lever return spring from the steering upper support bracket and steering tilt lever

(a) Using a centering punch, make the center of the 2 taped- hand bolts

(b) Using a drill, make a hole in the 2 steering lock set bolts and set a screw extractor

(c) Using the screw extractor, remove the steering column bracket assembly upper and upper steering column clamp from the steering column tube upper

(a) Widen the claw hung on the upper bracket by approximately 1.0 mm (0.039 in.) using a screwdriver

(b) Pull the transponder key amplifier toward the rear of the vehicle with the claw open

F051330

Screw Extractor

F051322E01

F051331

(c) Insert a screwdriver into the steering column bracket assembly upper as shown in the illustration Then tilt the screwdriver as shown in the illustration

to disengage the claw of the ignition lock cylinder assembly and remove the cylinder

HINT:

When the ignition lock cylinder assembly disengages, a click sound is heard

(a) Disconnect the un-lock warning switch assembly connector from the ignition or start switch assembly

(b) Remove the un-lock warning switch assembly toward the rear of the vehicle by pushing up the center part

(a) Using a screwdriver, remove the steering column

No 1 ring from the steering main shaft

(b) Using a snap ring expander, remove the snap ring and No 1 main shaft

(c) Remove the compression spring, bearing thrust collar and bearing from the No 1 main shaft

10 REMOVE NO.1 TILT STEERING SUPPORT COLLAR

(a) Using a brass bar, hammer and vise, gently strike the central part of the steering column bracket spacer and remove it

(b) Remove the No 1 tilt steering support collar from the steering column tube lower

F051332

F051323

F051324

REASSEMBLY

(a) Install the No 1 tilt steering support collar from the steering column tube lower

(b) Using a hammer and vise, install the steering column bracket spacer

NOTICE:

• The inclination of the steering column bracket spacer should be within +- 15 ° when

installing, as shown in the illustration.

• The turning angle of the No 1 tilt steering support collar should be within +- 15 ° when

installing.

(a) Install the steering main shaft onto the steering column tube upper and steering column tube lower

(b) Using a snap ring expander, install a new snap ring onto the main shaft

(c) Install the steering column No 1 ring onto the steering main shaft

(a) Install the un-lock warning switch assembly onto the steering column bracket assembly upper

(b) Connect the un-lock warning switch assembly connector to the ignition switch assembly

When the ignition lock cylinder assembly engages,

a click sound is heard

(b) Push up the transponder key amplifier and connect

it to the upper bracket

(a) Check that the steering mechanism is activated when removing the key

(b) Check that the steering mechanism is deactivated when inserting the key and turning it to ACC position

(a) Provisionally install the steering column bracket assembly upper and steering column upper clamp with the 2 new tapered-head bolts

(b) Tighten the 2 tapered-head bolts until the bolt heads break off

10 INSTALL TILT LEVER RETURN SPRING

(a) Install the tilt lever return spring onto the bracket and steering tilt lever

11 INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY

(a) Align the matchmarks on the steering intermediate shaft sub-assembly and steering main shaft assembly

(b) Temporarily install the steering intermediate shaft sub- assembly with the bolt

Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)

F051330E01

F051321E01

INSTALLATION

(a) Install the steering column assembly with the 2 nuts and bolt

(a) Align the matchmarks on the power steering gear and No 2 steering intermediate shaft

(b) Install the No 2 steering intermediate shaft onto the steering gear box with bolt C

Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) for bolt C

(a) Align the matchmarks on the steering column and steering sliding yoke

(b) Install the steering sliding yoke onto the steering column assembly and slide it upward

(c) Align the matchmarks on the intermediate shaft assembly No 2 and steering sliding yoke

sub-(d) Install the sliding yoke onto the intermediate shaft sub- assembly No 2 with bolts A and B

Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) for bolt

(a) Install the steering column hole cover with the 4 clips

IP-20 )

(See page IP-22 )

Lever Type Parking Brake) (See page IP-25 )

Pedal Type Parking Brake) (See page IP-25 )

10 INSTALL COWL SIDE TRIM BOARD LH (for Regular Cab) (See page IR-52 )

11 INSTALL COWL SIDE TRIM BOARD LH (for Access Cab) (See page IR-75 )

12 INSTALL COWL SIDE TRIM BOARD LH (for Double Cab) (See page IR-29 )

13 INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) (See page IR-52 )

14 INSTALL FRONT DOOR SCUFF PLATE LH (for Access Cab) (See page IR-75 )

15 INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab) (See page IR-29 )

17 INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY (See page WW-19 )

18 INSTALL SPIRAL CABLE SUB-ASSEMBLY (See page

RS-567 )

19 INSTALL UPPER STEERING COLUMN COVER

(a) Engage the claw and then install the steering column cover upper

20 INSTALL LOWER STEERING COLUMN COVER

(a) Engage the 2 claws

(b) Install the steering column cover lower with the 2 screws

21 INSTALL STEERING WHEEL ASSEMBLY

(a) Align the matchmarks on the steering wheel assembly and steering main shaft assembly

(b) Install the steering wheel assembly set nut

Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf)

22 INSTALL STEERING PAD (See page RS-558 )

23 INSTALL NO.3 LOWER STEERING WHEEL COVER

(a) Engage the claw and install the No 3 lower steering wheel cover onto the steering wheel assembly

F051329

24 INSTALL NO.2 LOWER STEERING WHEEL COVER

(a) Engage the claw and install the No 2 lower steering wheel cover onto the steering wheel assembly

25 PLACE FRONT WHEELS FACING STRAIGHT AHEAD

26 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)

27 INSPECT SRS WARNING LIGHT

(a) Coat a new vane pump housing oil seal lip with power steering fluid.

(b) Using SST and a press, install a new oil seal

SST 09950-60010 (09951-00280), 09950-70010

(09951-07100) NOTICE:

Make sure that the oil seal is installed facing in the correct direction.

(a) Coat the bushing inner surface of the vane pump housing front with power steering fluid

(b) Gradually insert the vane pump shaft

NOTICE:

Do not damage the vane pump housing oil seal lip in the vane pump housing front.

(a) Coat a new O-ring with power steering fluid and install it onto the vane pump housing front

(b) Coat a new O-ring with power steering fluid and install it onto the side plate

SST

Oil Seal F051271E01

Power Steering Fluid

F051272E01

F051267

(a) Align the dent of the cam ring with that of the side plate and install the cam ring with the inscribed mark facing outward.

(a) Install the vane pump rotor with the inscribed mark facing outward

(b) Coat the 10 vane plates with power steering fluid.(c) Install the vane plates with the round ends facing outward

(d) Using a snap ring expander, install a new snap ring onto the pulley shaft

(a) Coat a new O-ring with power steering fluid and install it onto the vane pump housing rear

(b) Align the straight pin of the vane pump housing rear with the dents of the cam ring, side plate and vane pump housing front, and install the vane pump housing rear with the 4 bolts

Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)

(a) Check that the pump rotates smoothly without making any abnormal noises

(b) Provisionally install the service bolt

Recommended service bolt:

Thread diameter:

10 mm (0.3937 in.) Thread pitch:

1.25 mm (0.0492 in.) Bolt length:

(a) Coat the O-ring with power steering fluid and install

it onto the power steering oil pressure switch

(b) Install the power steering oil pressure switch onto the vane pump

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

(a) Coat the compression spring and flow control valve with power steering fluid

(b) Install the compression spring and flow control valve

(c) Coat a new O-ring with power steering fluid and install it onto the pressure port union

(d) Install the pressure port union

Torque: 69 N*m (704 kgf*cm, 51 ft.*lbf)

10 INSTALL POWER STEERING SUCTION PORT UNION

(a) Coat a new O-ring with power steering fluid, and install it onto the suction port union

(b) Install the suction port union with the bolt

Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)

INSTALLATION

(a) Install the vane pump assembly with the 2 bolts

(a) Install a new gasket onto the pressure feed tube.(b) Install the pressure feed tube with the union bolt

Torque: 51 N*m (520 kgf*cm, 38 ft.*lbf)

(a) Connect the oil reservoir to pump hose No 1 with the clip

EM-5 )

TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)

(See page IN-5)

NO 1 (for 4WD and Pre-Runner) Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

F051258

F051257

REMOVAL

TERMINAL

NO 1 (for 4WD and Pre-Runner)

EM-5 )

(a) Disengage the clip and disconnect the return hose

(b) Remove the union bolt, then disconnect the pressure feed tube

(c) Remove the gasket from the pressure feed tube

(a) Disconnect the oil pressure switch connector

(b) Remove the 2 bolts and vane pump assembly

F051262

F051263

F051264

DISASSEMBLY

(a) Using SST, fix the vane pump assembly in a vise

NOTICE:

When using a vise, do not over tighten it.

SUB-ASSEMBLY

(a) Remove the 3 bolts and vane pump oil reservoir.(b) Remove the O-ring from the vane pump oil reservoir

(a) Remove the pressure port union

(b) Remove the O-ring from the pressure port union.(c) Remove the flow control valve and compression spring

SWITCH NOTICE:

Be careful not to drop or badly damage the oil pressure switch If damaged, replace it with a new one.

(a) Remove the 4 bolts and vane pump housing rear from the vane pump housing front

(b) Remove the O-ring from the vane pump housing front

(b) Remove the pulley shaft

(a) Remove the 10 vane plates

(b) Remove the vane pump rotor

(a) Remove the side plate from the vane pump housing front

(b) Remove the O-ring from the side plate

SST

F051266E01

(c) Remove the O-ring from the vane pump housing front

10 REMOVE VANE PUMP HOUSING OIL SEAL

(a) Using screwdriver, remove the oil seal

NOTICE:

Be careful not to damage the vane pump housing front.

INSPECTION

(a) Using a micrometer and caliper gauge, measure the oil seal clearance

Standard clearance:

0.021 to 0.043 mm (0.0008 to 0.0017 in.) Maximum clearance:

1.408 mm (0.0554 in.) Minimum length:

11.993 mm (0.4722 in.)

(b) Using a feeler gauge, measure the clearance between a side face of the vane pump rotor groove and vane plate

Length

N000372E03

Feeler Gauge

(a) Coat the flow control valve with power steering fluid and check that it falls smoothly into the flow control valve hole under its own weight

(b) Check the flow control valve for leakage Close one

of the holes and apply compressed air of 392 to 490

opposite side Confirm that the air does not flow out

of the end hole

If necessary, replace the vane pump assembly

(a) Using vernier calipers, measure the free length of the spring

Minimum free length:

36.9 mm (1.453 in.)

If it is not within the specification, replace the vane pump assembly

(a) If the union seat in the pressure port union is badly damaged, it could cause fluid leakage, so replace the vane pump assembly

(a) Coat a new vane pump housing oil seal lip with power steering fluid.

(b) Using SST and a press, install a new oil seal

SST 09950-60010 (09951-00280), 09950-70010

(09951-07100) NOTICE:

Make sure that the oil seal is installed facing in the correct direction.

(a) Coat the bushing inner surface of the vane pump housing front with power steering fluid

(b) Gradually insert the vane pump shaft

NOTICE:

Do not damage the vane pump housing oil seal lip in the vane pump housing front.

(a) Coat a new O-ring with power steering fluid and install it onto the vane pump housing front

(b) Coat a new O-ring with power steering fluid and install it onto the side plate

SST

Oil Seal F051271E01

Power Steering Fluid

F051272E01

F051267

(a) Align the dent of the cam ring with that of the side plate and install the cam ring with the inscribed mark facing outward.

(a) Install the vane pump rotor with the inscribed mark facing outward

(b) Coat the 10 vane plates with power steering fluid.(c) Install the vane plates with the round ends facing outward

(d) Using a snap ring expander, install a new snap ring onto the pulley shaft

(a) Coat a new O-ring with power steering fluid and install it onto the vane pump housing rear

(b) Align the straight pin of the vane pump housing rear with the dents of the cam ring, side plate and vane pump housing front, and install the vane pump housing rear with the 4 bolts

Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf)

(a) Check that the pump rotates smoothly without making any abnormal noises

(b) Provisionally install the service bolt

Recommended service bolt:

Thread diameter:

10 mm (0.3937 in.) Thread pitch:

1.25 mm (0.0492 in.) Bolt length:

(c) Using a torque wrench, check the pump rotating torque

Torque: 0.27 N*m (2.8 kgf*cm, 2.4 in.*lbf) or less

SWITCH

(a) Coat the O-ring with power steering fluid and install

it onto the power steering oil pressure switch

(b) Install the power steering oil pressure switch onto the vane pump assembly

Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

(a) Coat the compression spring and flow control valve with power steering fluid

(b) Install the compression spring and flow control valve

(c) Coat a new O-ring with power steering fluid and install it onto the pressure port union

(d) Install the pressure port union

(a) Install the vane pump assembly with the 2 bolts

(a) Install a new gasket onto the pressure feed tube.(b) Install the pressure feed tube with the union bolt

Torque: 51 N*m (520 kgf*cm, 38 ft.*lbf)

(c) Connect the return hose with the clip

EM-6 )

TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)

(See page IN-5)

NO 1 (for 4WD and Pre-Runner) Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

F051263

F051262

REMOVAL

TERMINAL

(a) Fix the steering wheel with the seat belt in order to prevent it from rotating

(c) Remove bolts A and B from the steering sliding yoke

(d) Slide the steering sliding yoke up and separate it from the steering intermediate shaft No 2

(e) Pull down the steering sliding yoke from the steering intermediate shaft to remove it

shaft No 2 and power steering link

(g) Remove bolt C from the steering intermediate shaft

No 2

(h) Slide the steering intermediate shaft No 2 up and remove it from the power steering link

(a) Remove the cotter pin and nut

(b) Using SST, separate the tie rod end from the steering knuckle arm

(a) Remove the bolt and separate the tube support bracket

(b) Using SST, loosen the flare nut and separate the pressure feed tube

(c) Disengage the clip and disconnect the return hose

(a) Remove the 2 bolts, 2 nuts and power steering link

DISASSEMBLY

(a) Using SST, remove the return tube

(a) Using SST, remove the 2 pressure tubes

(b) Remove the 4 O-rings from the pressure tubes

(a) Using SST, fix the power steering link between aluminium plates in a vise, as shown in the illustration

NOTICE:

When using a vise, do not over tighten it.

(a) Place matchmarks on the tie rod end, lock nut and rack end

(b) Loosen the lock nut and remove the tie rod end and lock nut

HINT:

The removal procedure for the RH side is the same as that for the LH side

(a) Remove the 2 rack boot clips

(a) Using pliers, remove the rack boot No 1 clamp

10 REMOVE STEERING RACK BOOT NO 2

11 REMOVE STEERING RACK END SUB-ASSEMBLY

(a) Using a screwdriver and hammer, unstake the claw washer

NOTICE:

Avoid any impact to the power steering rack.

(b) Using 2 SSTs, remove the 2 steering rack ends and

• Securely hold the steering rack end with SST.

12 REMOVE STEERING GEAR RACK GUIDE

(a) Using SST, remove the rack guide spring cap nut

(b) Using SST, remove the rack guide spring cap

(c) Remove the rack guide spring and rack guide

13 REMOVE POWER STEERING CONTROL VALVE ASSEMBLY

(a) Wind vinyl tape around the serrated portion of the control valve

(b) Remove the dust cover from the control valve housing

(c) Remove the 2 bolts and control valve w/ control valve housing

(d) Remove the O-ring from the control valve housing

(e) To prevent the oil seal lip form getting damaged, wind vinyl tape around the serrated portion of the control valve

from the control valve housing

(g) Using a screwdriver, remove the 4 control valve rings

SST 09950-60010 (09951-00250), 09950-70010

(09951-07150)

15 REMOVE CYLINDER END STOPPER

(a) Using a screwdriver and hammer, turn the cylinder end stopper clockwise until the wire end can be seen through the service hole

(b) Using a screwdriver and hammer, turn the cylinder end stopper counterclockwise, and remove the wire and cylinder end stopper

16 REMOVE POWER STEERING RACK

17 REMOVE POWER STEERING RACK BUSH

(a) Remove the rack bush from the power steering rack

(b) Using a screwdriver, remove the O-ring from the rack bush

(c) Using SST, remove the rack bush oil seal

19 REMOVE RACK STEERING PISTON RING

(a) Using a screwdriver, remove the piston ring and ring

O-NOTICE:

Be careful not to damage the groove for the piston ring.

INSPECTION

(a) Flip the ball joint stud back and forth 5 times as shown in the illustration before installing the nut

(b) Using a torque wrench, turn the nut continuously at

a rate of 2 to 4 seconds per turn and check the torque reading on the 5th turn

Torque: 0.83 to 3.43 N*m (8.5 to 35.0 kgf*cm,

7.35 to 30.36 in.*lbf)

(a) Using a dial indicator, check the power steering rack for runout, teeth wear and damage

Maximum runout:

0.3 mm (0.012 in.)

If necessary, replace the power steering link assembly

(b) Check the back surface for wear and damage

If necessary, replace the power steering link assembly

R010955

ZK08184

ZX09355

(a) Coat a new O-ring with power steering fluid and install it onto the power steering rack.

(b) Expand a new piston ring with your fingers

NOTICE:

Be careful not to over expand the rack steering piston ring.

(c) Coat a new piston ring with power steering fluid

(d) Install the piston ring onto the power steering rack, and position it with your fingers

• Make sure that the cylinder tube oil seal is installed facing in the correct direction.

• Take care not to reverse the cylinder tube oil seal direction when installing.

(a) Install SST onto the power steering rack

HINT:

If necessary, scrape the burrs off the power steering rack teeth end and burnish

(b) Coat SST with power steering fluid

(c) Install the power steering rack into the rack housing

(d) Remove SST

(a) Using SST and a press, install a new rack bush oil seal onto the rack bush

SST 09950-60010 (09951-00400), 09950-70010

(09951-07100) NOTICE:

Make sure that the rack bush oil seal is installed facing the correct direction.

(b) Coat a new O-ring with power steering fluid and install it onto the rack bush

(c) To prevent the rack bush oil seal lip from being damaged, wind vinyl tape around the rack end and apply power steering fluid

(d) Install the rack bush onto the power steering rack

(a) Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing

(b) Install a new wire into the cylinder end stopper

(c) Using a screwdriver, turn the cylinder end stopper clockwise by 400 to 500°

Rack Teeth End