1. Clean all the disassembled parts, and check for wear, damage or any other faults, then repair or replace as necessary.
2. When disassembling, check the inside of gearbox assembly for water. If any water is found, carefully check the boot for damage, and the input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts.
|
No. |
Parts |
Inspection |
Corrective action |
|
1 |
Input shaft |
(1) Bent input shaft (2) Damage on serration |
If there is excessive bend or damage, replace the entire gearbox assembly. |
|
2 |
Dust seal |
(1) Crack or damage (2) Wear |
If the outer wall slips, the lip is worn out or damage is found, replace it with a new dust seal. |
|
3 |
Rack & pinion |
Poor mating of rack with pinion |
(1) Adjust the backlash properly. By measuring the turning torque of the gearbox and the sliding resistance of rack, check if the rack & pinion engages uniformly and smoothly with each other. (refer to “SERVICE LIMIT”) (2) Pull out the entire rack to allow viewing of the teeth, and check for damage. If a problem of either (1) or (2) is found, replace the entire gearbox assembly. |
|
4 |
Gearbox unit |
(1) Bending of the rack shaft (2) Bending of the cylinder portion (3) Crack or damage on cast iron portion |
Replace the gearbox assembly with a new part. |
|
(4) Wear or damage on rack bushing |
If the free play of the rack shaft in the radial direction is out of the specified range, replace the gearbox assembly with a new part. (refer to “SERVICE LIMIT”) | ||
|
(5) Wear on input shaft bearing |
If the free play of the input shaft in the radial direction is out of the specified range, replace the gearbox assembly with a new part. (refer to “SERVICE LIMIT”) | ||
|
5 |
Boot |
Crack, damage or deterioration |
Replace |
|
6 |
Tie-rod |
(1) Looseness of ball joint (2) Bend of tie-rod |
Replace |
|
7 |
Tie-rod end |
Damage or deterioration of dust seal |
Replace |
|
8 |
Adjusting screw spring |
Deterioration |
Replace |
|
9 |
Boot clip |
Deterioration |
Replace |
|
10 |
Sleeve |
Damage |
Replace |
|
11 |
Pipe |
(1) Damage to flared surface (2) Damage to flare nut (3) Damage to pipe |
Replace |
Make a measurements as follows. If it exceeds the specified service limits, adjust or replace.
NOTE:
When making a measurement, hold the gearbox assembly in a vise using the ST. Do not hold the gearbox in a vice by inserting aluminum plates etc. between the vise and gearbox assembly.
| ST 926200000 | STAND |
Rack shaft sliding resistance:
Service limit:
400 N (41 kgf, 90 lbf) or less
3. RACK SHAFT FREE PLAY IN THE RADIAL DIRECTION
Right swing
Service limit:
0.19 mm (0.0075 in) or less
On condition
L: 5 mm (0.20 in)
P: 122.6 N (12.5 kgf, 27.6 lbf)
Left swing
Service limit:
Direction 
0.3 mm (0.012 in) or less
Direction 
0.15 mm (0.0059 in) or less
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kgf, 22 lbf)
In radial direction
Service limit:
0.18 mm (0.0071 in) or less
On condition
P: 98 N (10 kgf, 22 lbf)
In axial direction
Service limit:
0.5 mm (0.020 in) or less
On condition
P: 20 — 49 N (2 — 5 kgf, 4 — 11 lbf)
5. TURNING RESISTANCE OF GEARBOX
Using the ST, measure gearbox turning resistance.
| ST 34099PA100 | SPANNER |
Service limit:
Maximum allowable resistance:
9.33 N (0.95 kgf, 2.10 lbf) or less
Difference between right and left turning resistance:
Less than 20%
|
(1) |
Power cylinder |
(3) |
Rack piston |
(5) |
Input shaft |
|
(2) |
Cylinder |
(4) |
Rack |
(6) |
Valve housing |
1. If a fluid leak is found, clean the fluid completely from the suspect area, and turn the steering wheel 30 to 40 times to the left and right from lock to lock, with the engine running, and check again for leaks immediately, and also after a few hours have passed.
2. Cause and solution for oil leakage from “a”.
The oil seal is damaged. Replace the valve assembly with a new part.
3. Cause and measure for oil leakage from “b”.
The torsion bar O-ring is damaged. Replace the valve assembly with a new part.
4. Cause and measure for oil leakage from “c”.
The pipe is damaged. Replace the faulty pipe or O-ring.
5. If the leak is other than a, b, c or if oil is leaking from the gearbox, move the right and left boots toward tie-rod end side, respectively, with the gearbox mounted to the vehicle, and remove fluid from surrounding areas. Then, turn the steering wheel from lock to lock 30 to 40 times with the engine running, then re-inspect the leaking area immediately after and several hours after this operation.
(1) Cause and solution for oil leakage from “d”.
The cylinder seal is damaged. Replace the rack bushing with a new part.
(2) Cause and solution for oil leakage from “e”
There are two possible causes. Perform the following step first. Remove the pipe assembly B from the valve housing, and close the circuit using ST.
| ST 926420000 | PLUG |
Turn the steering wheel from lock to lock 30 to 40 times with the engine running, then inspect the leaking section immediately after and several hours after this operation.
• If leakage from “e” is found again:
The oil seal of pinion and valve assembly is damaged. Replace the pinion & valve assembly with a new part. Or replace the oil seal and the parts that are damaged during disassembly with new parts.
• If oil stops leaking from “e”:
The oil seal of rack housing is damaged. Replace the oil seal and parts that are damaged during disassembly with new parts.