Contents: Removal ⇓ Checking and preliminary adjustment…⇓ Steering traction resistance ⇓ Checking the corrugated protective…⇓ Disassembly ⇓ Checking the toothed rack ⇓ Checking the bearing ⇓ Other checks ⇓ Assembly ⇓
Removal
1. Place the vehicle on a lift and raise it.
6. Raise the car.
7. Loosen the bolt securing the clamp for the pressure and return pipes of the power steering and remove the clamp.
Warning: When removing the steering gear, be careful not to damage the protective boots.
Checking and preliminary adjustment before installation
Secure the steering gear in a vice with jaws covered with soft material.
Caution: When securing the steering gear in a vice, wrap the steering gear in a cloth and be careful not to damage it when the vice is tightened.
2. If the preload is not within the required value, first adjust the tightening torque of the plug and recheck the preload of the gear.
3. If adjusting the plug tightening torque does not produce positive results, check or replace the plug components.
Steering traction resistance
1. Perform 10 steering rod deflections.
2. Use a dynamometer to measure the force required to move the steering rod.
Deflection force: 2-5 N
3. If the measured value exceeds the standard value, replace the steering tie rod assembly.
Attention! If the measured value is below the nominal value, but not less than 44 N, the steering rod turns smoothly and without play, it can be installed on the vehicle.
Checking the corrugated protective cover
1. Visually inspect the corrugated protective cover for damage and deterioration of its properties.
2. Make sure the protective cover is installed in the correct position.
3. If the corrugated protective cover has defects, replace it.
Disassembly
1. Remove the tie rod end from the tie rod.
6. While slowly moving the toothed rack, drain the fluid from the steering gear housing.
7. Use a chisel to bend back the lock washer securing the steering rod to the toothed rack.
8. Unscrew the steering rod from the toothed rack.
Caution: When removing the steering rod, be careful not to turn the toothed rack.
11. Loosen the lock nut and remove the spring, stop and bushing from the steering gear housing.
15. Remove the rack bushing and rack from the rack housing.
16. Remove the O-ring from the rack bushing.
Caution: Be careful not to damage the valve cylinder bore diameter in the steering gear housing.
21. Using a special tool, remove the seal and ball bearing from the valve body.
Checking the toothed rack
1. Check the rack for damaged or worn teeth.
2. Check the working edges of the seal for damage.
3. Check the rack for deflection or twisting.
4. Check the oil seal for damage or wear.
5. Check the oil seal for damage or wear.
Checking the bearing
1. Check the bearing for jamming or extraneous noise when rotating.
2. Check the bearing for excessive play.
3. Check for missing needle bearing rollers.
Other checks
1. Check the surface of the steering gear housing cylinder bore for damage.
2. Check the protective cover for damage, aging and cracks.
Assembly
1. Lubricate the sliding surface of the rack oil seal.
Recommended fluid: PSF-3
2. Install the oil seal in a strictly defined position in the rack housing.
7. Install the toothed rack into the steering gear housing and press on the toothed rack sleeve until the groove in the rack housing aligns with the groove in the sleeve and install the retaining ring.
12. Install the bushing, stop and spring in the order shown in the figure. Apply sealant to the threaded part of the plug before installation.
13. Set the rack to the central position and install the bushing, stop and spring. Apply sealant to the threaded part of the plug before installation. Using a special tool, tighten the plug to a tightening torque of 12 N·m. Loosen the cap by 30–60° and tighten the lock nut to the required tightening torque.
Tightening torque: 50–70 Nm
14. Tighten the fluid supply tube to the required torque and install the rubber element on the glue.
15. Place grease into the corrugated protective boot and install it into the groove of the steering rod.
Recommended lubricant: silicone grease
16. Secure the corrugated protective cover with a clamp.
Note: A new clamp and clip must be used to attach the new bellows cover.
17. Check that the corrugated protective cover is not twisted.
18. Fill the protective boot with lubricant, install it on the ball joint of the tie rod end and secure it with a snap ring.
Recommended lubricant:
- A: POLY LUB GLY 801 KB or equivalent
- B: SHOWA SUNLIGHT MB2 or equivalent
- Protective case: THREE BOND
9. Connect the tie rod ends to the left and right steering knuckles.
10. Install the wheels.
11. Screw in the universal joint mounting bolt to the steering gear.
12. Fill the power steering fluid reservoir.
13. Bleed the power steering hydraulic drive.