Withdrawal
1. Remove the air intake pipe.
2. Remove the clamps securing the pressure and return hoses to the steering gear housing.
3. Drain the fluid from the power steering hydraulic drive.
4. Disconnect pressure head and returnable hoses from a case of steering transfer.
5. Turn out a bolt connecting the universal joint and a shaft of a gear wheel of a steering transfer.
6. Remove the bracket, dust cover, and dust cover mounting plate.
7. Raise the car.
8. Remove the front wheels.
9. Remove the cotter pins and unscrew the nuts securing the trunnions of the ball joints of the tie rod ends to the steering knuckles. With a puller 09568–31000, press the pins of the ball joints of the tie rod ends from the steering knuckles.
10. Remove the right stabilizer bar mounting bracket.
11. Disconnect the front muffler.
12. Turn out bolts and remove clips of fastening of steering transfer and pressure head and return tubes.
13. Move the steering gear and get it on the right side of the car.
Warning! When removing the steering gear, be careful not to damage the protective covers.
Inspection and pre-adjustment before installation
Fix the steering gear in a vise, the jaws of which are covered with soft material.
Warning! When fixing the steering gear in a vise, wrap the steering gear with a cloth and be careful not to damage it when squeezing the vise.
Gear preload
1. Measure the preload by turning the gear with special tool 09565-11100 one revolution every 4-6 seconds. Also measure the starting force of the rack. Full gear preload: 0.6 - 1.3 Nm.
Warning! Measure the preload for the full travel of the rack.
2. If the preload is not correct, first adjust the plug torque and recheck the gear preload.
3. If adjusting the plug torque does not give positive results, check or replace the plug elements.
Tie Rod Deflection Resistance
1. Perform 10 tie rod deflections.
2. Using a dynamometer, measure the force that must be applied to deflect the tie rod. Tie rod deflection force: 8–22 N.
3. If the measured value exceeds the nominal value, replace the tie rod assembly.
Attention! If the measured value is below the nominal value and the tie rod turns smoothly and without play, it can be installed on the vehicle. However, if the measured value is below 4.3 N, replace the tie rod.
Checking the bellows
1. Visually inspect the bellows for damage or deterioration.
2. Make sure the protective cover is installed in the correct position.
3. If the bellows are defective, replace them.
Disassembly
1. Remove the tie rod end from the tie rod.
2. Use a screwdriver blade to remove the protective cover of the ball joint of the tie rod end.
3. Remove the band tie securing the bellows.
4. Remove the clip securing the bellows.
5. Move the bellows to the tie rod.
Attention! When replacing the bellows, check the steering gear for rust.
6. Remove the guide tube from the gear housing.
7. When moving the rack slowly, drain the fluid from the steering gear housing.
8. With a chisel, remove the lock washer that secures the tie rod to the rack.
9. Remove steering draft from a rack.
Warning! When removing the tie rod, be careful not to turn the gear rack.
10. Turn out a counternut of fastening of a stopper.
11. Using a 14 mm wrench, remove the plug from the steering gear base.
12. Remove the spring, stop and bushing from the steering gear housing.
13. Turn out two bolts and remove the case of the valve.
14. Using a screwdriver blade, turn the rack stopper clockwise until the end of the retaining ring comes out of the groove in the steering gear housing.
15. When the end of the retaining ring comes out of the hole in the rack cylinder housing, use a screwdriver blade to turn the steering stopper counterclockwise and remove the retaining ring.
16. Remove the O-ring from the rack bushing.
17. Remove the oil o-ring from the rack bushing.
18. Tap the valve body out of the casing with a plastic mallet.
19. Using the special tool 09565–21000, remove the oil seal and ball bearing from the valve body.
20. Remove the ball bearing from the steering gear housing.
Warning! Be careful not to damage the valve cylinder in the steering gear housing.
21. Using special tools 09573–21200, 09555–21000, remove the oil seal from the steering gear housing.
Warning! Be careful not to damage the rack cylinder in the steering gear housing.
Checking the rack
1. Check the rack for damage or wear on the teeth.
2. Check the oil seal contact surfaces for damage.
3. Check the gear rack for kinking or twisting.
4. Check the O-ring for damage or wear.
5. Check the oil seal for damage or wear.
Gear valve check
1. Check the gear valve for damage or wear to the teeth.
2. Check the oil seal contact surfaces for damage.
3. Check the O-ring for damage or wear.
4. Check the oil seal for damage or wear.
Bearing check
1. Check the bearing for any jamming or abnormal noise as it rotates.
2. Check the bearing for excessive play.
3. Check for missing needle bearing.
Other checks
1. Check the surface of the steering gear housing cylinder for damage.
2. Check the protective cover for damage, aging and cracks.
Assembly
1. Lubricate the sliding surface of the rack oil seal. Recommended lubricant: PSF-3.
2. Install the reverse washer and oil seal in the steering gear housing in the position shown in the illustration.
3. Lubricate the sliding surface of the oil seal of the rack bushing. Recommended lubricant: PSF-3.
4. Install the oil seal in the steering gear bushing.
5. Lubricate the O-ring and install it in the rack bushing.
6. Lubricate the rack teeth. Recommended lubricant: SAE J310, NLGI #2.
Warning! Do not block the vent hole in the rack with grease.
7. Install the gear rack in the steering gear housing. Then install the bushing and rack stopper.
8. Press the gear rack stopper until a groove appears and, turning the stopper, install the retaining ring.
Warning! The circlip must not be visible through the hole in the rack housing.
9. Using the special tool, install the oil seal and ball bearing into the valve body.
10. Lubricate the valve assembly with oil and recommended grease and install it in the steering gear case.
11. Lubricate with oil and install the seal into the valve body using the special tool. Install the valve body assembly with O-ring into the steering gear case.
12. Establish a lock washer and steering draft and in two places caulk a shoulder of a washer.
- 1. Align the tabs of the lock washer with the notches on the steering gear case.
- 2. Always use a new lock washer.
13. Install bushing, stop and spring in the order shown in the figure. Before installing, apply sealant to the threaded part of the plug.
14. Center the rack and pinion and install the bushing, stop and spring. Before installing, apply sealant to the threaded part of the plug. Using a special tool, tighten the plug with a torque of 15 Nm. Loosen the cap 30-60°and tighten the locknut to the correct torque. Tightening torque: 50–70 Nm.
15. Tighten the guide tube to the required tightening torque and install the rubber element on the adhesive.
16. Lubricate the bellows and install them in the tie rod groove. Recommended lubricant: silicone grease.
17. Fasten the corrugated protective cover with a new collar.
18. Check that the bellows are not twisted.
19. Fill the protective boot with lubricant, install it on the ball joint of the tie rod end and secure with a retaining ring.
Recommended material:
- A: POLY LUB GLY 801 KB or equivalent
- B: SHOWA SUNLIGHT MB2 or equivalent
- Protective case: THREE BOND
20. Establish steering drafts so that length of the left and right steering drafts was identical. Steering rod length: 204.5 mm.
21. Check gear preload.
Installation
1. On the right side of the vehicle, install the steering gear.
2. Install the dust cover and plate.
3. Secure the dust cover and plate with a new clamp.
4. Connect the steering gear shaft to the steering shaft.
5. Further installation is carried out in the reverse order of removal.
6. Bleed the hydraulic drive of the power steering.