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SECTION 6D

MANUAL STEERING GEAR

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in B unless otherwise noted.

DESCRIPTION AND OPERATION

MANUAL RACK AND PINION

The manual rack and pinion steering system consists of two main components: the rack and the pinion. The motion of the pinion is transferred through the pinion teeth that mesh with the teeth on the rack, which moves the rack. The force is then transmitted through the arms on the struts, which turn the wheels.

COMPONENT LOCATOR

MANUAL RACK AND PINION STEERING GEAR

(Left-Hand Drive Shown, Right-Hand Drive Similar)

D105B401
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  1. Manual Steering Gear
  2. Steering Gear Bracket
  3. Cotter Pin
  4. Castellated Nut
  5. Tie Rod End
  6. Tie Rod End Lock Nut
  7. Rack and Pinion Boot Clamp
  8. Rack and Pinion Boot
  9. Rack and Pinion Boot Wire Clamp
  10. Tie Rod
  11. Shock Damper Ring
  12. Steering Rack Gear
  13. Bulkhead Retainer
  14. Bulkhead Bushing
  15. Steering Gear Housing
  16. Steering Gear Bracket Bushing
  17. Packing
  18. Dust Cover
  19. Pinion Plug
  20. Steering Pinion Gear
  21. Roller Bearing
  22. Rack Bearing
  23. Adjuster Spring
  24. Adjuster Plug

DIAGNOSTIC INFORMATION AND PROCEDURES

MANUAL RACK AND PINION STEERING GEAR

Condition
Probable Cause
Correction
Excessive Play or Looseness in the Steering System
  • Poor adjustment of steering gear.
  • Perform straight-ahead check.
  • Improperly installed tie rods.
  • Tighten the tie rods.
Rattling Noise in the Steering Gear
  • Improper and insufficient lubrication.
  • Lubricate the rack and pinion assembly.
  • Improperly installed steering gear mounting.
  • Tighten the steering gear mounting bolts.
  • Improperly installed tie rods.
  • Tighten the tie rods.

STRAIGHT-AHEAD CHECK

After all the necessary operations on the steering gear are completed, check the exact straight-ahead position of the steering in each case.
With the vehicle on the floor, place the steering wheel in the straight-ahead position. Mark the centerline of both tires on the floor. Turn the steering wheel all the way to the right and mark the new centerline of both tires on the floor.
Application
Tire
Specified Valve
Inside Angle
145, 155
37.5-41.5°
175
32.9-36.9°
Outside Angle
145, 155
31.5-35.5°
175
28.5-32.5°


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Step Action Value(s) Yes No
1
Place the steering wheel in the straight-ahead position.
Is the wheel in the correct position?
-
Go to Step 2
-
2
Is the steering wheel off center by more than 5 degrees?
-
Go to Step 4
Go to Step 5
3
The pinion is displaced on the rack. The steering pinion position must be corrected.
Is the repair complete?
-
Go to Step 2
-
4
Remove steering wheel and center on the spindle splines.
Is the repair complete?
-
Go to Step 2
-
5
Turn the steering wheel all the way to the right. Measure the inner and the outer angles of the tire centerline compared to the straight-ahead centerline. Do the angles match the value specified?
Refer to "Straight-Ahead Check" in this section
System OK
Go to Step 6
6
The rack assembly was not assembled correctly.
Repair as needed.
Is the repair complete?
-
Go to Step 5
-

STEERING WHEEL RESTORATION

  1. Turn the steering wheel fast to the right and left and turn it slowly as the same way.
  2. Check if the steering wheel restoration for the wheel turning to right and the one to the left are same.
  3. Turn the steering wheel to 903 about 1-2 seconds and loosen the steering wheel during the low speed driving.
  4. If the steering wheel restores above 70%, the steering wheel restoration is OK.
  5. If the restoration is poor, check the tire pressure, steering gear preload, and steering gear operation. And repair the fault.

CHECK THE TURNING RESISTANCE OF THE TIE ROD END OR TIE ROD

  1. Turn the ball joint of the tie rod end or the tie rod about 10 times.
  2. Use a spring balance to check the turning resistance of each ball joint.

D105B302
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Application
Specified Value
Tie Rod End Ball Joint
0.49-3.43 N•m
(4.5-30 lb-in.)
Tie Rod Ball Joint
0.49-3.43 N•m
(4.5-30 lb-in.)
  1. If the values exceed the specified values, replace the tie rod end or the tie rod.
  2. But, If the ball joint of the tie rod end or the tie rod falls down of itself, replace it.

ADJUST THE FREE LOAD OF THE STEERING GEAR

  1. Place the steering wheel in the straight-ahead position.
  2. Raise and suitably support the vehicle.
  3. Check the torque of the adjuster plug.
  4. When the measured torque is below the specification value or the measured torque is over the specification value, adjust the tightening torque.

D105B303
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REPAIR INSTRUCTIONS

ON-VEHICLE SERVICE



D105B501
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TIE ROD END

Tools Required

KM-507-B Ball Joint Remover

Removal Procedure

  1. Remove the wheel. Refer to Section 2E, Tires and wheels.
  2. Disconnect the tie rod and from the steering knuckle.


  3. D105B502
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  4. Remove the tie rod end.


  5. D105B503
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D15B504B
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Installation Procedure

  1. Install the tie rod end.
  2. Install the tie rod lock nut (1).
  3. Tighten
    Tighten the tie rod end lock nut to 35-55 N•m (25-41 lb-ft).

  4. Connect the tie rod end to the knuckle.
  5. Install the tie rod end castellated nut (2).
  6. Tighten
    Tighten the castellated nut to 30-55 N•m (21-41 lb-ft).

  7. Install the split pin.
  8. Install the wheel. Refer to Section 2E, Tires and Wheels.
  9. Make the toe-in adjustment by turning the tie rod adjuster. Refer to Section 2B, Wheel Alignment.


D105B505
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RACK AND PINON BOOT

Removal Procedure

  1. Remove the tie rod end. Refer to "Tie Rod End" in this section.
  2. Remove the tie rod end lock nut.


  3. D105B506
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  4. Remove the rack and pinion boot.


  5. D105B507
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D105B508
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Installation Procedure

  1. Install the rack and pinion boot with the clamp and the wire clamp.
  2. Install the tie rod end nut.
  3. Install the tie rod end. Refer to "Tie Rod End" in this section.


D105B509
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RACK AND PINION STEERING GEAR ASSEMBLY

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Remove the intermediate shaft lower pinch bolt. Refer to Section 6E, Steering Wheel and Column.
  2. Remove the wheels. Refer to Section 2E, Tires and Wheels.
  3. Disconnect the tie rod end from the steering knuckle. Refer to "Tie Rod End" in this section.
  4. Remove the front exhaust pipe nuts. Refer to Section 1G, Engine Exhaust.


  5. D105B510
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  6. Remove the steering gear assembly from the vehicle.


D15B511A
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Installation Procedure

  1. Install the mounting to the steering gear assembly.
  2. Install the steering gear assembly.
  3. Install the steering gear bracket with the bolts.
  4. Tighten
    Tighten the steering gear bracket bolts to 50-55 N•m (36-41 lb-ft).

  5. Install the front exhaust pipe nuts. Refer to Section 1G, Engine Exhaust.
  6. Connect the tie rod end to the steering knuckle. Refer to "Tie Rod End" in this section.
  7. Install the wheels. Refer to Section 2E, Tires and Wheels.
  8. Install the intermediate shaft lower pinch bolt. Refer to Section 6E, Steering Wheel and Column.

UNIT REPAIR



D105B701
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TIE ROD END BOOT

Disassembly Procedure

  1. Remove the tie rod end. Refer to "Tie Rod End" in this section.
  2. Remove the tie rod end boot.
  3. a. Tie rod end boot.


D105B702
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Assembly procedure

    Important : Coat the grease inside of the boot.

  1. Install the boot to the tie rod end.
  2. Install the tie rod end wire clamp.
  3. Install the tie rod end. Refer to "Tie Rod End" in this section.


D105B703
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RACK AND PINION

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Disassembly Procedure

  1. Remove the rack and pinion steering assembly from the vehicle. Refer to "Rock and Pinion Assembly" in this section.
  2. Remove the rack and pinion boot.


  3. D105B704
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    D105B705
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  4. Remove the tie rod


  5. D15B706A
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    Important : Clothe the rack gear with a cloth before vising the rack gear.

    Notice : Do not vise the rack gear over two teeth face.



    D105B707
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    D105B708
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  6. Remove the rack bearing.


  7. D105B709
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  8. Remove the pinion and bearing assembly.
  9. Important : Do not reuse the removed pinion plug.



    D105B710
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    D105B711
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  10. Remove the rack gear toward the driver side of the steering gear.
  11. a. Rack gear.

    Notice : Remove the rack gear toward the driver side of the steering gear to prevent the bulk head in the steering gear housing from damaging in installing and removing the rack gear.



D105B712
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Inspection Procedure

  1. Inspect the rack gear deformation and damage.


  2. D105B713
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  3. Inspect the pinion and bearing assembly damage.


  4. D105B714
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  5. Inspect the tie rod end boot and the rack and pinion boot for damage.


  6. D105B715
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  7. Inspect the steering gear housing for crack, deformation and wear.
  8. a. Steering gear housing.


    D105B716
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  9. Inspect the tie rod end ball joint and tie rod ball joint for damage.
  10. After inspecting the parts, replace the defected parts.


D105B717
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Assembly Procedure

    Important : Coat the all turn, contact and rub surface with grease.

  1. Clean the all parts removed.
  2. Install the rack gear.


  3. D15B718A
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  4. Install the pinion and bearing assembly.
  5. Tighten
    Tighten the pinion plug to 40-60 N•m (30-44 lb-ft).



    D105B719
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  6. Install the rack bearing.


  7. D15B720A
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  8. Install the tie rod.
  9. Important : Clothe the rack gear with a cloth before vising the rack gear.

    Notice : Do not vise the rack gear above two teeth face.

    Tighten
    Tighten the tie rod to 80-120 N•m (59-89 lb-ft).



    D105B721
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  10. Install the shock damper ring to the tie rod ball joint.
  11. a. Tie rod ball joint.


    D105B722
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  12. Install the rack and pinion boot.
  13. Install the tie rod end. Refer to "Tie Rod End" in this sections.
  14. Install the rack and pinion steering gear assembly to the vehicle. Refer to "Rack and Pinion Steering Gear Assembly" in this section.
  15. Adjust the free load of the steering gear. Refer to "Diagnosis" in this section.

SPECIFICATIONS

GENERAL SPECIFICATIONS

Application
Description
Type
Rack and Pinion
Overall Gear Ratio
21 : 1
Steering Angle
145,155 Tire
Inside
39.5° ±2°
Outside
33.5° ±2°
175 Tire
Inside
34.9 ° ±2°
Outside
30.5 ° ±2°
Lubricant
Rack Gear
POLYUREAS
Ball Joint
SYNTHETICS OILS & LI SOAPS
Locktite Type
DAC SPEC ADHESIVE SEALANT #520414

FASTENER TIGHTENING SPECIFICATIONS

Application
N•m
Lb-Ft
Lb-In
Tie Rod End Castellated Nut
30 - 55
21 - 41
-
Tie Rod End Lock Nut
35 - 55
25 - 41
-
Steering Gear Bracket Bolts
50 - 55
36 - 41
-
Tie Rod-to-Rack Gear
80 - 120
59 - 89
-
Pinion Plug
40 - 60
30 - 44
-
Pinion Preload
Refer to "Diagnosis" in this section.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS TABLE


D105B101
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KM-507-B
Ball Joint Remover


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