1 INDEX

Models FA and FB POWER STEERING 67-1

67-61E-13

CHAPTER 67
POWER STEERING
Models FA and FB

TROUBLESHOOTING ...............................................................67 - 2

SPECIAL TOOLS ......................................................................67 - 3

DIAGNOSIS ...............................................................................67 - 4

POWER STEERING GEAR BOX ..............................................67 - 9

POWER STEERING PUMP .......................................................67 - 19

FLUID RESERVOIR ..................................................................67 - 28

INSPECTION OF THE POWER STEERING SYSTEM

AFTER ASSEMBLING ..............................................................67 - 31

67

67-2 POWER STEERING
Symptoms
Fluid leakage
To locate fluid leaks
clean leaked fluid
and check fluid level
first
Hard steering
(Excessive steering effort)
Basic inspection items
• Fluid level, fluid
cleanliness
• Air in fluid
• Tire pressure
• Front alignment
• Steering linkage
• Universal joint
Abnormal noise
Basic inspection items
• Fluid level, fluid
cleanliness
• Air mixed in fluid
• Pump piping
• Steering linkage
1 page 1
Models FA and FB
TROUBLESHOOTING
Possible cause Remedy
Pump ....................................................... Replace pump
Gear box
• Oil seal, O-ring other than seal lock nut ...... Replace oil seal or O-ring
and drain plug
•Seal lock nut ................................................ Repair lock nut
Line joints ............................................... Repair leaky parts
One side is hard
• Steering gear is faulty ................................. Hydraulic test
Replace piston sub-assembly
Both sides are hard
• Steering gear pump is faulty ....................... Hydraulic test
Measure pump discharge
pressure – Replace pump
Measure system hydraulic pressure
– Replace piston sub-assembly
• Incorrect preload of the sector shaft ........... Adjust sector shaft preload
bearing
Hard, when starting to steer
• Incorrect preload of the sector shaft ........... Adjust sector shaft preload
bearing is off
Pump
• Air sucked in at input pipe ........................... Repair and bleed air or replace
pump
Gear ........................................................ Replace piston sub-assembly
 1 page 1
Models FA and FB POWER STEERING 67-3

SPECIAL TOOLS
Prior to starting of the power steering overhaul, it is necessary to have these special tools.

Illustration Tool No. Tool name

09740 - 1010 SYSTEM GAUGE

09659 - 1060 ADAPTER

09657 - 1290 GUIDE

09650 - 1260 PITMAN ARM PULLER

09434 - 1110 PRESS

09434 - 1130 PRESS

09434 - 1140 PRESS

 1 page 1
67-4 POWER STEERING Models FA and FB

DIAGNOSIS
THOROUGHLY CLEAN ALL JOINTS OF THE
STEERING GEAR, RESERVOIR, PUMP AND
LINES BEFORE INSPECTING THE POWER
STEERING SYSTEM.
NOTE:
Any foreign matter (fluid, dust, grime) in
fluid causes valves and seals to clog up,
thus lowering hydraulic pressure, causing
machine malfunction and shortening the
pump service life.
POWER STEERING PUMP
6 7
1. CHECKING FLUID LEVEL
Check fluid level by means of the level gauge
in the power steering reservoir. Replenish fluid
if necessary. Inspect for any leaks and repair
if necessary.
NOTE:
● Use only power steering fluid.
● Do not overfill the reservoir tank.
● Replace old fluid with new fluid after
overhauling any gear or pump compo-
nents.
● Power steering fluid ............Refer to
RECOMMENDED LUBRICANT LIST.

4
8

3
2
9
1
10

11
12 SM67-343

15 14 6
13

6
1. Pump shaft 9. Rear body
2. Ball bearing 10. Vane
3. Front body 11. Rotor
4. Plug 12. Side plate
5. Spring 13. Knock pin
6. O-ring 14. Needle roller bearing
7. Relief valve 15. Oil seal
8. Flow control valve assembly

Fig. 1
 1 page 1
Models FA and FB POWER STEERING 67-5

FLUID RESERVOIR

7 4

SM67-398

1. Cap 5. Oil filter

2. Oil reservoir 6. Oil filter gasket
3. Spring 7. Oil strainer
4. Filter cover

Fig. 2
 1 page 1
67-6 POWER STEERING Models FA and FB
2. FLUID LEAK INSPECTION
Check for any fluid leakage from the gear,
pump, reservoir, line and hoses. Check es-
pecially for any leaks from the line joints. If
fluid leakage does not stop after tightening
such joints, replace or overhaul these parts.
NOTE:
If fluid leakage is not stopped promptly,
fluid level decreases and causes power
steering malfunction and pump jamming.
1. Fluid leakage from the power steering
gear.
Inspect for fluid leakage from the worm
shaft, end plug, sector shaft, side cover
top cover and adjuster screw.
NOTE:
When replacing the worm shaft oil seal,
replace the entire kit.
2. Fluid leakage from the pump and tank.
Check for any fluid leakage from the
seals. Replace the entire seal kit if nec-
essary .
3. Fluid leakage from lines.
Check for fluid leakage from line joints
(joining flare nuts or hoses) and hose end
joints (nuts or line connections).
If there is any leakage:
a. Tighten the nut or hose clamp.
b. Replace lines if any damage, cracks or
corrosion on seal surfaces is found.
c. Replace hoses if any damage or cracks
are found.
3. SYSTEM TEST
Conduct a system test using a system gauge
after replacing or overhauling the power steer-
ing system components or when troubles such
as hard steering arise.
Thoroughly clean all lines and joints of the
steering gear, pump and tank before conduct-
ing the system test. Also check for any fluid
leakage from each component part. Clean the
system gauge before using and always store
it in a clean condition.
1. Bleeding air in the system.
If there is any air mixed in the fluid, elimi-
nate it in the following manner.
a. Block the rear wheels then jack up the
front wheels and support them over a
stand.
b. Pour pump fluid into the reservoir within
MIN LEVEL of the dipstick.
c. Turn the steering wheel from lock to lock.
d. Start the engine and keep turning the
steering wheel from lock to lock until all
air is eliminated from the fluid.
e. Stop the engine and fill the reservoir
within MAX LEVEL of the dipstick.
f. Lower the front wheels.
NOTE :
● The fluid reservoir must not be empty
while bleeding air in the system.
● The fluid level must not change greater
than 5 mm (0.20 in.) after stopping the
engine. Otherwise, repeat the air bleed-
ing operation.
 1 page 1
Models FA and FB POWER STEERING 67-7

2. Hydraulic test

GAUGE
STOP
VALVE

GEAR BOX SYSTEM GAUGE ENGINE

PUMP

RESERVOIR
TANK

Fig. 3

a. Mounting the system gauge. Hydraulic pressure:

NOTE:
Be sure to apply wheel stoppers in rear
tires.
WARNING
● When jacking up the front axle, place
a jack correctly to the axle, and then
lift up the axle.
● Do not get under the vehicle when it
is supported by a jack only. It is very
dangerous as the jack might slip.
● Use safety stands which have suffi-
cient strength and stability to support
the vehicle.
a) Set the system gauge as shown in
Fig. 3.
b) Make sure that the gauge stop valve is
fully open.
c) As in the air bleeding operation, check
for fluid leakage from hose joints.
b. Measuring the system’s hydraulic pres-
sure.
Idle the engine and turn the steering
wheel to a full stop.
Apply a force of approx. 15 kg (33 lb) to
the steering wheel and measure the hy-
draulic pressure (both right and left).
80 - 85 kg/cm2 (1,138 - 1,208 lb/sq.in.)
at 50 - 60°C (122 - 140°F) of the fluid
temperature.
NOTE:
● Perform the test quickly.
● If the above pressure is not attained,
measure the pump discharge pressure.
c. Measuring the pump discharge pressure.
a) Idle the engine and close the stop valves
slowly.
b) Measure the pump discharge pressure
with the stop valve fully closed.
Pressure:
80 - 85 kg/cm2 (1,138 - 1,208 lb/sq.in.)
at 50 - 60°C (122 - 140°F) of the fluid
temperature.
c) Open the stop valve fully.
NOTE:
Do not keep the stop valve closed for
more than 15 seconds.
d. Removing the system gauge.
a) Stop the engine.
b) Remove the system gauge lines and
store it properly.
c) Bleed air in the system and make sure
that fluid does not leak from the hose
joints.
 1 page 1
67-8 POWER STEERING Models FA and FB

3. Final Inspection
a. Start the engine and turn the steering
wheel fully from right to left and make
sure that its movement is smooth.
NOTE:
When turning the steering wheel, support
the front tires on a turntable and idle the
engine. The steering force in this condition
should be less than 2 kg (4.4 Ib).

b. Turn the steering wheel to full lock and

apply force of approx. 15 kg (33 lb) to the
steering wheel and check the gear box,
pump, reservoir and joints for leakage.
 1 page 1
Models FA and FB POWER STEERING 67-9

POWER STEERING GEAR BOX

3
7

8
5 4

5
9

4
10 6
4
4
11

12
5
4
4
7

SM67-476

1. Seal lock nut 5. Oil seal 9. Piston sub-assembly

2. Bushing 6. Sector shaft 10. Dust seal
3. Side cover sub-assembly 7. Dust cover 11. Housing
4. O-ring 8. Retainer ring 12. Pitman arm

Fig. 1

67-10 POWER STEERING Models FA and FB
OBSERVE THE FOLLOWING INSTRUCTIONS
BEFORE DISASSEMBLY AND ASSEMBLY.
1. The piston sub-assembly should never
be disassembled .
2. All functional parts should be clean.
Blow dirty parts off with dry compressed
air, then clean them with volatile metal
cleanser. Never use brushes or cloths.
3. Handle rubber parts, seals, etc., in clean
conditions. Any worn parts should be
replaced immediately. Never use volatile
metal cleanser to clean rubber parts.
Always use power steering fluid.
DISASSEMBLY
1.
SM12-086
Fig. 2
2.
SM67-460
Fig. 3
SM67-475
Fig. 4
1 page 1
4. For disassembling and assembling, only
use power steering fluid.
5. Standard tools can generally be used for
assembling and disassembling, though
special tools may also be required.
When using special tools, read the
instructions carefully, and never use
standard tools in place of special tools.
6. Before removing the steering gear box,
drain fluid in the gear box and lines.
Mount the gear unit in a vise.
REMOVE THE PITMAN ARM.
1. Remove the pitman arm mounting nut and lock
washer with a socket wrench.
NOTE: Width of socket wrench: 46 mm (1.81 in.)
2. Remove the pitman arm with a special tool.
Special tool: Pitman arm puller (09650 - 1260)
REMOVE THE SIDE COVER SUB-ASSEMBLY.
1. Remove the seal lock nut.
NOTE: Fit a hexagonal wrench 6 mm (0.24 in.) on the
adjusting screw.
2. Remove the side cover sub-assembly mounting nut
and bolt.
3. Tighten the adjusting screw with a hexagonal wrench
6 mm (0.24 in.) and remove the side cover.
 1 page 1
Models FA and FB POWER STEERING 67-11

4. Remove the O-ring from the side cover sub-assem-

bly and gear housing.
NOTE: Replace the O-ring with a new one.

SM67-457 SM67-458
Fig. 5
3. REMOVE THE SECTOR SHAFT SUB-ASSEMBLY.
1. Position the sector shaft work at right angle to the
housing.
2. Tap the sector shaft sub-assembly lightly with a plas-
tic-faced hammer for removal.
NOTE: Be careful not to damaged the internal gear
housing.

SM67-474
Fig. 6
4. REMOVE THE POWER PISTON SUB-ASSEMBLY.
1. Remove the dust cover.
2. Remove the power piston sub-assembly mounting
bolt.
3. Hold the piston of the power piston sub-assembly
with one hand and turn the worm shaft unit the O-
ring at the cover is detached from the gear housing.

SM67-473 WARNING
Fig. 7 Keep the power piston sub-assembly horizontal. If
it is inclined, the piston may fall due to its own
weight.

4. When the O-ring at the cover is detached from the

gear housing, pull out the power piston sub-assem-
bly by hand.
5. Remove the O-ring from the power piston sub-as-
sembly and gear housing.

NOTE: Replace the O-ring with a new one.

 1 page 1
67-12 POWER STEERING Models FA and FB

INSPECTION AND REPAIR

1. INSPECT THE WORM SHAFT STARING TORQUE.
Check if the staring torque of the worm shaft is within
the standard value with a special tool.
If the value is not within the standard value, replace
the power piston sub-assembly with a new one.
Special tool: Measuring adapter (09659 - 1060)
Standard : 6 kg·cm (0.4 lb·ft) or less
SM67-472
Fig. 8
2. INSPECT THE BACKLASH OF THE BALL NUT.
Mount the power piston sub-assembly in a vise as
shown in the figure. Check if the backlash of the
ball nut is within the standard value with a dial gauge.
If the value exceeds the limit value, replace the power
piston sub-assembly with a new one.
Standard: 0 mm
Limit: 0.05 mm (0.0019 in.)
SM67-471
Fig. 9
3. INSPECT THE SECTOR SHAFT.
Mount the sector shaft in a vise using aluminium soft
jaws.
Check if the adjusting screw thrust clearance is within
the standard value with a dial gauge.
If the value is not within the standard value, replace
the sector shaft sub-assembly with a new one.
Standard: 0 - 0.015 mm (0 - 0.0059 in.)
SM67-470
Fig. 10
4. REPLACE THE WORM SHAFT OIL SEAL.
1. Remove the snap ring with snap ring pliers.
2. Remove the oil seal with a flat-bladed screwdriver.
NOTE: Be careful not to damage the power piston
and top cover.

SM67-468 SM67-469
Fig. 11
3. Install a new oil seal with a special tool.
NOTE: Apply lithium grease to the oil seal lip.
Special tool: Oil seal guide (09657 - 1290)

SM67-467
Fig. 12
 1 page 1
Models FA and FB POWER STEERING 67-13

4. Install the snap ring with snap ring pliers.

SM67-469
Fig. 13
5. REPLACE THE SECTOR SHAFT OIL SEAL.
(Gear housing side)
1. Remove the O-ring and oil seal with a flat-bladed
screwdriver.
NOTE: Be careful not to damage the gear housing.
2. Install the new oil seal O-ring.
NOTE: ● Apply ATF to the oil seal lip and O-ring.
● Pay attention to the installation direction
SM67-466
of the oil seal.
Fig. 14
6. REPLACE THE SECTOR SHAFT OIL SEAL.
(Side cover side)
1. Remove the oil seal and bushing with a flat-bladed
screw driver.
NOTE: Be careful not to damage the side cover.
2. Install a new oil seal.
NOTE: ● Apply ATF to the installation direction of
the oil seal.
SM67-465
● Pay attention to the installation direction
Fig. 15
of the oil seal.
3. Install the new bushing.
 1 page 1
67-14 POWER STEERING Models FA and FB

7. REPLACE THE SEALS OF THE POWER PISTON.

1. Remove the dust seal and O-ring with a flat-bladed
screwdriver.
NOTE: Be careful not to damage the power piston
spline.
2. Install a new O-ring and dust seal.
NOTE: ● Apply lithium grease to the O-ring and
dust seal.
SM67-463 SM67-464
● Do not extend the dust seal locally during
Fig. 16
installation.
Excessive extension of the dust seal may
result in the loose part being cut when
installing the power piston on the gear
housing.

8. INSPECT THE HOUSING AND SIDE COVER SUB-AS-

SEMBLY.
1. Check the housing inside for any wear or damage.
2. Check the threads of the line for any damage.
3. Check the bearing for any damage.
NOTE: If any damage is found on the bearing, replace
the housing and/or side cover sub-assembly.

SM67-531
Fig. 17
9. INSPECT THE SECTOR SHAFT SUB-ASSEMBLY.
1. Check the teeth for wear and damage.
2. Check the bearing rolling surface for wear and
damage.
3. Check the taper serration for damage.
4. Check the adjust bolt threads for damage.

SM67-532
Fig. 18
5. Check the staked ring screw for looseness.
NOTE: In checking for cracks in the sector shaft, use
color check instruments, etc.

SM67-533
Fig. 19
 1 page 1
Models FA and FB POWER STEERING 67-15

10. INSPECT THE PISTON SUB-ASSEMBLY.

NOTE: Take adequate precautions when checking
the functions of the piston sub-assembly or
it may fall apart when held vertically.
1. Make sure that the worm shaft and power piston have
no play and turn smoothly.
2. Check the power piston outer rim and rack for any
damage.
SM67-428A NOTE: If any damage is found, replace the piston
Fig. 20 sub-assembly.
3. Check that the screw and lock nut of centering bolts
2 2 are tight enough and must not to be turned by hand.
NOTE: Never adjust the centering bolt, replace with
the piston sub-assembly.

3
SM67-429A
Fig. 21
 1 page 1
67-16 POWER STEERING Models FA and FB

ASSEMBLY AND ADJUSTMENT

BEFORE ASSEMBLING, MAKE SURE THAT ING FLUID LIGHTLY ON ALL PARTS. FOR THE
THERE IS NO DUST/DIRT ON THE END FACES PARTS TO BE PRESSED IN, APPLY POWER
OF THE HOUSING, TOP COVER AND SIDE STEERING FLUID TO PREVENT DAMAGE.
COVER. WASH AND APPLY POWER STEER-

ASSEMBLY AND ADJUSTMENT

1. INSTALL THE PISTON SUB-ASSEMBLY.
1. Install the O-ring on the power piston sub-assembly
and gear housing.
NOTE: Apply ATF to the O-ring.
2. Insert the power piston sub-assembly into the gear
housing and fix it with bolts.
NOTE: Hold the dust seal with your fingers to pre-
SM67-457 SM67-458
vent damage when inserting the piston.
Fig. 22
3. Install the dust cover.

DUST COVER NOTE: Apply lithium grease inside the dust cover.

SM67-366
Fig. 23
4. Tap the oil seal into the top cover using the special
tool.

Special Tool: OIL SEAL GUIDE (09657 - 1290)

5. Fix the top cover and tighten the nuts to the speci-
fied torque.
Tightening torque: 750 - 1,050 kg·cm (55 - 76 lb·ft)
SM67-430
Fig. 24
 1 page 1
Models FA and FB POWER STEERING 67-17

2. INSTALL THE SIDE COVER SUB-ASSEMBLY AND

SECTOR SHAFT.
1. Turn the worm shaft to align the ball nut gear center
with the sector shaft mounting hole.
2. Install a new O-ring on the gear housing.
3. Insert the sector shaft into the gear housing.
NOTE: To protect the oil seal, use protective tape on
the spline of the sector shaft.
SM67-462
Fig. 25
4. Install a new O-ring on the side cover.
NOTE: ● Apply ATF to the O-ring.
● Be careful not to let the valve pin and
bushing fall.
5. Attach the side cover to the gear housing using the
adjusting screw.
NOTE: Check that the guide of the power piston is
at the center.
SM67-475
Make sure that the valve pin does not inter-
Fig. 26
fere with the guide.

6. Fix the side cover with nuts and bolts to the speci-
fied torque.
Tightening torque: 750 - 1,050 kg·cm (55 - 76 lb·ft)

SM67-431
Fig. 27
3. PRELOAD ADJUSTMENT
1. Adjust the frinction torque of the worm shaft with the
adjusting screw to within in the standard value.
Standard: 3.5 - 10 kg·cm (3.1 - 8.6 lb·in.)
2. Tighten the seal lock nuts to the specified torque.
Tightening torque: 1,000 kg·cm (72 lb·ft)
NOTE: Always use a new seal lock nut.
3. After tightening the seal lock nut, check the worm
SM67-461 preload again.
Fig. 28
 1 page 1
67-18 POWER STEERING Models FA and FB

4. INSTALL THE PITMAN ARM.

1. Install the dust cover.
2. Align the pitman arm with the sector shaft alignment
mark for installation.
3. Install and tighten the washer and nut to the speci-
fied torque.
Tightening torque: 3,000 - 4,000 kg·cm (217 - 289 lb·ft)

SM67-459
Fig. 29
 1 page 1
Models FA and FB POWER STEERING 67-19

POWER STEERING PUMP

14 13

12
9
15

12
9
11
10

4 9
3
2
7 8
6
1 5

SM67-344

1. Retainer ring 6. Oil seal 11. Side plate

2. Woodruff key 7. Needle roller bearing 12. Spring
3. Pump shaft 8. Front body 13. Rear body
4. Ball bearing 9. O-ring 14. Flow control valve
5. Snap ring 10. Cartridge 15. Plug

Fig. 1
 1 page 1
67-20 POWER STEERING Models FA and FB

REMOVAL
BEFORE DISCONNECTING THE PUMP AND LINES, CLEAN
AWAY ANY FOREIGN MATTER.
1. DISCONNECT THE LOW PRESSURE HOSE AND HIGH
PRESSURE HOSE FROM THE PUMP.

NOTE: Drain fluid into a container.

SM67-434
Fig. 2
2. REMOVE THE TWO BOLTS AND TAKE OUT THE PUMP.
DISASSEMBLY
1. CLAMP THE GEAR IN THE VISE.

NOTE: ● Do not tighten the vise too tight.

● Cover the gear with a rag etc. to prevent
damaging it.

2. LOOSEN AND REMOVE THE CLAMP NUT.

SM67-084
Fig. 3
3. CLAMP THE PUMP IN VISE.

NOTE: ● Do not tighten the vise too tight.

● Cover the gear with a rag etc. to prevent
damaging it.

4. USING A COMMERCIAL PULLER, REMOVE THE GEAR.

SM67-085
Fig. 4
5. REMOVE THE PUMP SHAFT.
1. Using snap ring pliers, remove the retainer ring.

WARNING
The retainer ring is spring steel and may pop out of
the groove. Wear safety glasses to protect your
eyes.

SM67-401
Fig. 5
2. Using a sliding hammer and adapter, remove the
pump shaft with bearing.

SM67-402
Fig. 6
 1 page 1
Models FA and FB POWER STEERING 67-21

6. SEPARATE THE FRONT BODY AND REAR BODY.

1. Loosen and remove the bolts.

SM67-403
Fig. 7
2. Remove the front body with knock pin.
3. Remove the O-ring.

SM67-404
Fig. 8
7. REMOVE THE ROTOR AND VANES.

NOTE: Be careful that the rotor and vanes do not fall

out.

SM67-405
Fig. 9
8. REMOVE THE SIDE PLATE.
1. Using a plastic hammer, tap the rear body, and re-
move the cam ring, side plate and spring.

NOTE: Avoid gripping the side plate with pliers as

this could damage it.

2. Remove the O-ring.

SM67-406
Fig. 10
9. REMOVE THE FLOW CONTROL VALVE.
Remove the plug, spring and flow control valve.

NOTE: Do not drop, scratch or nick the flow control

valve.

SM67-407
Fig. 11
 1 page 1
67-22 POWER STEERING Models FA and FB

INSPECTION
1. INSPECT THE PUMP SHAFT.
1. Check the pump shaft for wear or damage.
2. Check that the pump shaft bearing rotates smoothly.
If the bearing is scratched or damaged, replace it.

SM67-408
Fig. 12
3. If necessary, replace pump shaft bearing.
a. Using snap ring pliers, remove the shaft spring ring.
WARNING
The retainer ring is spring steel and may pop out from
groove. Wear safety glasses to protect your eyes.

b. Using a press or special tool, press out the bearing.

SM67-409 SM67-053 Special Tool: Press (09434 - 1140)
Fig. 13

PRESS c. Using a press or special tool, press in the bearing.

Special Tool: Press (09434 - 1130)
SPECIAL
TOOL
DRIVE
SHAFT
d. Install the shaft spring.
BEARING

SM67-012 SM67-080
Fig. 14
2. INSPECT THE OlL SEAL.
Check the oil seal for wear or damage.

NOTE: If the oil seal is scratched or damaged,

replace it.

SM67-087
Fig. 15
3. REPLACE THE OIL SEAL, IF NECESSARY.
1. Remove the oil seal.
Using a screwdriver, remove the oil seal.

NOTE: Do not scrape or damage the front body

inside.

SM67-079
Fig. 16
 1 page 1
Models FA and FB POWER STEERING 67-23

2. Oil seal inserting direction.

A Insert the oil seal as shown in Fig. 17.
B
NOTE: To prevent oil leakage from oil seal due to lip
INSERTING wear, apply lithium-base multipurpose grease
NEEDLE DIRECTION
ROLLER BEARING to A and B.

SM67-093
Fig. 17
3. Using special tool and press, press in the oil seal.
SPECIAL
TOOL Special Tool: Press (09434 - 1110)
OIL
SEAL

SM67-053 SM67-089
Fig. 18
4. INSPECT THE NEEDLE ROLLER BEARING
Check the needle roller bearing rotates smoothly.

NOTE: If the needle roller bearing is scratched or

damaged, replace the front body sub-assem-
bly.

5. IF NECESSARY, REPLACE THE NEEDLE ROLLER

SM67-086
BEARING.
Fig. 19
1. Remove the needle roller bearing.
2. Using a press, press the needle roller bearing into
the front body.

6. INSPECT THE ROTOR AND CAM RING.

1. Check the rotor surface for wear, scratches or scor-
ing.
2. Check the cam ring inner surface for wear, scratches
or scoring.
If a problem is detected, replace the cartride assem-
bly .

SM67-410
Fig. 20
 1 page 1
67-24 POWER STEERING Models FA and FB

7. INSPECT THE SIDE PLATE AND FRONT BODY SUR-

FACE “A”.
1. Check the side plate and front body surface “A” for
SURFACE abrasions or flaws.
If a problem is detected, replace the side plate.

SM67-083
Fig. 21
INSPECT THE FLOW CONTROL VALVE.
1. Check the flow control valve for wear or damage.
2. Apply power steering fluid to the valve and check
that it falls smoothly into the valve hole by its own
weight.
If a problem is detected, replace the flow control valve
assembly.
Power steering fluid:
SM67-103 Refer to RECOMMENDED LUBRICANTS LIST.
Fig. 22

ASSEMBLY
A
BEFORE ASSEMBLING, CLEAN ALL THE PARTS AND
LUBRICATE THEM WITH POWER STEERING FLUID.
Power steering fluid:
B
Refer to RECOMMENDED LUBRICANTS LIST.
NOTE: There are three different valves in diameter,
therefore be careful that the mark on both
valve and the pump body are always
SM67-563 SM67-094A matched.
IDENTIFICATION MARK
PUMP BODY (A) VALVE (B)
TWO LINE
0

ONE LINE
1

NO LINE
2

Fig. 23 SM67-553

1. INSTALL THE FLOW CONTROL VALVE.

1. Clamp pump in vise.
2. Install the flow control valve and spring, and then
tighten the plug.

Tightening Torque: 500 - 800 kg·cm (37 - 57 lb·ft)

SM67-411 SM67-412
Fig. 24
 1 page 1
Models FA and FB POWER STEERING 67-25

2. INSTALL THE PUMP SHAFT.

1. Install the oil seal as shown in Fig. 25.
A—Oil seal
A B—Front body
B

SM67-081A
Fig. 25
2. Using special tool or press, install the pump shaft
into the front body.

Special Tool: Press (09434 - 1140)

SM67-082A
Fig. 26
3. Retainer ring installing direction.

NOTE: When installing the retainer ring, place the

chamfer side facing toward ball bearing as
shown in figure.

CHAMFER
SM67-70B
Fig. 27
4. Install the retainer ring with snap ring pliers.

WARNING
The retainer ring is spring steel and may pop out
from the groove. Wear safety glasses to protect your
eyes.

SM67-413
Fig. 28
3. INSTALL THE CAM RING.
DOT MARK 1. Install the knock pin into the front body.
2. Install the cam ring with the pin hole aligned with
knock pin.

NOTE: At this point, make sure that the dot mark in

CAM RING
the side surface is positioned toward the rear
body.
SM67-095 SM67-096
Fig. 29
 1 page 1
67-26 POWER STEERING Models FA and FB

4. INSTALL THE ROTOR AND VANE.

1. Install the rotor with the cut spline side facing toward
the front body.

FRONT
BODY

SM67-414 SM67-097
Fig. 30
2. Install the vane with the round end facing outward.

OUTSIDE

SM67-415 SM67-098
Fig. 31
5. INSTALL THE SIDE PLATE AND SPRING.
A q 1. Place the side plate on the cam ring with pin hole
A aligned with the knock pin.
w
2. Place the spring on the side plate hole.

NOTE: Apply lithium-base grease to A

q—Spring
w—Side plate
SM67-099
Fig. 32
6. INSTALL THE REAR BODY.
1. Install the O-ring into the rear body.
NOTE: Apply the lithium base grease to the O-ring.
2. Using a press, press in the rear body and then tighten
the bolts.
Tightening Torque: 300 - 450 kg·cm (22 - 32 lb·ft)

SM67-416 SM67-417
Fig. 33
7. INSPECT PUMP SHAFT ROTATION CONDITION.
Check that the pump shaft rotates smoothly without
abnormal noise.

SM67-418
Fig. 34
 1 page 1
Models FA and FB POWER STEERING 67-27

8. INSTALL THE GEAR TO THE PUMP.

Tightening Torque: 850 kg·cm (62 lb·ft)

NOTE: Cover the gear with a rag etc. to prevent dam-
aging it.

SM67-104
Fig. 35

INSTALLATION
1. INSTALL THE PUMP.
1. Install the pump to the engine and tighten the bolts.

Tightening Torque: 480 kg·cm (35 lb·ft)

2. Connect the low pressure hose and high pressure

hose, and then tighten the joint bolt.
SM67-434
Fig. 36
Tightening Torque: 400 - 500 kg·cm (29 - 36 lb·ft)
 1 page 1
67-28 POWER STEERING Models FA and FB

FLUID RESERVOIR

SM67-339

1. Cap
2. Oil strainer
3. Reservoir sub-assembly

Fig. 1
 1 page 1
Models FA and FB POWER STEERING 67-29

INSPECTION
BEFORE REMOVING THE RESERVOIR CAP, CLEAN AWAY
ANY FOREIGN MATTER FROM RESERVOIR.
INSPECT THE OIL STRAINER
If the oil stainer is damaged, replace it with a new one.

SM67-339C
Fig. 2
REPLACEMENT OF POWER STEERING FLIUD
1. BLOCK THE REAR TIRES AND JACK UP THE FRONT
OF VEHICLE THEN SUPPORT IT WITH STANDS.

SM67-421
Fig. 3
2. TURN THE STEERING WHEEL FROM LOCK TO LOCK
WHILE DRAINING FLUID.
3. AFTER DRAINING FLUID, INSTALL THE DRAIN PLUG
TO POWER STEERING GEAR BOX.

SM67-282B
Fig. 4
4. FILL THE RESERVOIR WITH POWER STEERING
FLUID.

Power steeling fluid: Refer to RECOMMENDED LU-

BRICANTS LIST.

SM67-420A
Fig. 5
5. TURN THE STEERING WHEEL FROM LOCK TO LOCK
SEVERAL TIMES AND CHECK THE FLUID LEVEL.
Check the fluid level and add power steering fluid if
necessary.
NOTE: Check that the fluid level is between MIN and
MAX.

SM67-422
Fig. 6
 1 page 1
67-30 POWER STEERING Models FA and FB

BLEEDING OF POWER STEERING SYSTEM

1. CHECK THE FLUID LEVEL IN THE RESERVOIR.
Check the fluid level and add power steering fluid if nec-
essary.
Power steering fluid: Refer to RECOMMENDED LU-
BRICANTS LIST.

2. START THE ENGINE WITH IDLING AND TURN THE

STEERING WHEEL FROM LOCK TO LOCK SEVERAL
TIMES.

3. STOP THE ENGINE AND CHECK THE FLUID LEVEL

IN THE RESERVOIR.
Check the fluid level and add power steering fluid if nec-
essary.
Power steering fluid: Refer to RECOMMENDED LU-
BRICANTS LIST.
 1 page 1
Models FA and FB POWER STEERING 67-31

INSPECTION OF THE POWER STEERING SYSTEM AFTER

ASSEMBLlNG
AFTER REPLACING OR OVERHAULING THE
POWER STEERING SYSTEM COMPONENTS,
CONDUCT THE FOLLOWING.

1. FILL THE RESERVOIR WITH POWER STEERING

FLUID.
NOTE: ● Power steering fluid: Refer to RECOM-
MENDED LUBRICANT LIST.
● Do not over fill the reservoir.

WARNING
When checking the fluid level of the power steer-
SM67-420A ing reservoir or adding fluid to the reservoir, be
Fig. 1 careful not to contaminate fluid by letting dirt fall
into the reservoir. Fluid contaminated with dirt can
result in a shorter life of the pump, and can result
in personal injury and/or property damage due to
improper operation of relief valve, central valve, etc.

2. BLEEDING THE AIR IN THE SYSTEM. 2. Flow-control Valve

Refer to Section for DIAGNOSIS ON PAGE
67-6 or 67-30 of this chapter.
3. CONDUCT A SYSTEM TEST.
Refer to Section for DIAGNOSIS ON PAGE
67-6, 7 of this chapter.
1. Relief Valve
Increase the engine revolution up to
about 2,000 r.p.m. and slowly tighten the
stop valve, paying attention to the rise
in pressure.
Correct, if the fluid pressure is;
80 - 85 kg/cm2 (1,138 - 1,208 lb/sq.in.)
Tighten the stop valve and set the fluid
pressure at 50 kg/cm2 (711 Ib/sq.in.).
Increase the engine revolution up to
about 1,500 r.p.m, then reduce the revo-
lution suddenly. (This operation should
be repeated more than 5 times.)
Correct, if the set pressure, 49.5 - 50.5
kg/cm 2 (703.89 - 718.11 Ib/sq.in.) is
recovered immediately.
 1 page 1
67-32 POWER STEERING Models FA and FB

INSPECT THE STEERING SYSTEM FOR OPERATING

ABILITY.
1. Position the vehicle’s front wheels on turntables, then
start the engine and keep at idling speed.

NOTE: Block the rear wheels.

SM67-394
Fig. 2
2. Check that the steering wheel turns smoothly
without any shocks or abnormal resistance, when it
is turned full range.

SM67-282B
Fig. 3
3. Measure the steering wheel turning force.

Assembly Standard: Less than 2 kg (4.41 lb)

SM12-373A
Fig. 4
4. Check the steering wheel play.

Assembly Standard: 15 - 35 mm (0.60 - 1.37 in.)

WARNING
Excessive steering wheel play may adversely
affect vehicle handling. This can result in personal
injury and/or property damage.
SM67-284B
Fig. 5