Group 37 Steering

GROUP 37 STEERING
SPECIFICATIONS ............................................................................. 37-2
STRUCTURE AND OPERATION

1. Steering System ......................................................................... 37-3
2. Fluid Flow ................................................................................... 37-3
3. Power Steering Booster .............................................................. 37-4
4. Power Steering Oil Pump ............................................................ 37-6
TROUBLESHOOTING ...................................................................... 37-8
ON-VEHICLE INSPECTION AND ADJUSTMENT

1. Oil Leakage and Replacement of Power Steering Oil ................ 37-12
2. Bleeding of Power Steering System .......................................... 37-13
3. Performance Verification Test of Power Steering System ......... 37-14
4. Steering Wheel Play .................................................................. 37-15
5. Steering Column Looseness ..................................................... 37-15
6. Inspection of Rods and Arms for Looseness ............................ 37-15
7. Inspection of Power Steering System Mounts for Looseness .... 37-16
8. Play in Drag Link, Power Cylinder End and Tie Rod Ends .......... 37-16
9. Inspection of Dust Cover of Drag Link, Connecting Link Rod,
Power Cylinder End and Tie Rod End ........................................ 37-17
STEERING COLUMN ...................................................................... 37-18
POWER STEERING BOOSTER AND DRAG LINK ....................... 37-24
POWER STEERING OIL PUMP

<UNISIA JKC STEERING SYSTEMS Product> ............................... 37-44
<KYB Product> ............................................................................. 37-50
POWER STEERING OIL TANK ...................................................... 37-58
CONNECTING LINK ROD <FS> .................................................... 37-60
POWER CYLINDER <FS> .............................................................. 37-66
37-1
SPECIFICATIONS
Steering wheel, steering shaft, power steering booster and power cylinder
Specifications
Item
Except FS FS
Type 2-spoke type
Steering wheel
Outer diameter mm 480
Steering shaft Type Universal joint type (tilt and telescopic type)
Manufacturer Unisia JKC Steering Systems
Type Ball nut type
Power steering booster Form Integral form
Gear ratio 21.4 to 23.8 22.4
Cylinder diameter mm 110 100
Manufacturer – KYB
Power cylinder Cylinder bore × stroke mm – 50 × 270
3
Oil quantity dm {L} – 0.56 {0.56}
Power steering oil pump

Specifications
Item
Except FS FS
Manufacturer Unisia JKC Steering Systems KYB
Model Vane type
3
Delivery rate cm {mL}/rev. 20 {20} 24.6 {24.6}
3
Adjusted flow volume dm {L}/min. 17 {17} 19 {19}
0 +5
Adjusted pressure (relief valve) MPa {kgf/cm2} 13.73 0
–0.69 {140 –7 } 12.3 +0.5
–0.2 {125 –2 }
Permissible revolutions rpm 350 to 3700 350 to 4800
37-2
STRUCTURE AND OPERATION 37
1. Steering System
2. Fluid Flow
37-3
3. Power Steering Booster
• A rotary valve is adopted for the valve, the center of the power steering. For steering reaction force and return of
the valve, the valve operates lightly and smoothly at low speed by means of the torsion bar, and provides stable
steering feel up to high speed.
37-4
37
3.1 When moving straight forward
• As equal pressure is applied to cylin-
der chambers A and B on both sides
of the piston, the piston is placed in
neutral position.
3.2 When turning the steering

wheel
• When the steering wheel is turned, the
stub shaft is twisted, which causes the
rotor to shut off oil supply passages to
cylinder chamber A. As a result, pres-
sure difference is caused between cyl-
inder chamber A and B, and the piston
moves, facilitating rotation of the worm
shaft.
The illustration shows a condition
when the steering wheel is turned to
the left.
3.3 When hydraulic circuit fails

• The turning force of the stub shaft
alone turns the worm shaft.
37-5
4. Power Steering Oil Pump
37-6
37
4.1 Flow control valve
(1) Operation of flow control valve as-
sembly
(1.1) When not functioning (oil pump
in operation at low speed)
• Oil pressure in the chamber A is weak-
er than the combined force of oil pres-
sure in the chamber B and tension of
the flow control spring, and the flow
control valve remains stationary.
(1.2) When functioning (oil pump in

operation at middle to high
speeds)
• Oil pressure in the chamber A over-
comes the combined force of oil pres-
the flow control spring, and the flow
control valve is shifted.
• Port is made open to release oil, and
the flow rate to power steering booster
is maintained constant.
(2) Operation of relief valve

• When the combined force of oil pres-
the flow control spring overcomes oil
pressure in the chamber A, the flow
control valve is shifted. Further in-
creased oil pressure in the chamber B
pushes the relief valve to open port,
thus preventing excessive oil pressure
from going to pressure chamber.
37-7
TROUBLESHOOTING
Symptoms
Steering angle not enough or different be-

Steering wheel play excessive and
Noise from oil pump (low whirring)

Steering wheel pulled to one side
Steering wheel return not smooth
Noise from oil pump (squeaking)

Steering wheel heavy to operate
Oil pump oil pressure abnormal

Noise from oil pump (grinding)
Steering wheel does not turn
Reference Gr
tween right and left

Steering shimmy
Oil leakage
unstable
Possible causes
Thrust bearing damaged or worn O O O
Ball and groove of ball screw worn O O O
Air bleeding insufficient O
Hydraulic fluid viscosity unsuitable O
Power steering booster system faulty O O O
Operation of flow control valve faulty O
Rack and gear of ball screw unit worn O
Faulty power steering mechanism
Bearing of sector shaft worn O O

Power steering booster mounting bolts
O
and nuts loose
Play between ball screw unit and sector
O O
shaft unsuitable
Valve control edge damaged, or seal ring
O O
and O-ring for control broken
Hydraulic fluid in power steering system
O
faulty
Adjustment of rack engagement turning
O O
torque faulty
Hydraulic circuit clogged O O
Sector shaft gear worn O
Stub shaft serration damaged or worn O
Power steering booster unit faulty O O O O O
O-ring and oil seal faulty O
Application of sealant faulty O
Universal joint abnormally worn or dam-
O O O
aged, or poorly greased
Faulty steering column
and link mechanism
Link deformed O
Drag link ball joint loosened O O
Tie rod end ball joint loosened O O
Tie rod bent O
Pitman arm mounting position incorrect O
Right and left turning center of steering
O
wheel displaced
37-8
37
Symptoms




Reference Gr

Steering shimmy
Oil leakage
unstable
Possible causes
King pin poorly greased O O
Front wheel alignment (toe-in, camber
O O O O
and caster) incorrect
Thrust bearing damaged O
Wheel hub bearing worn out or damaged O O O Gr26
King pin or bushing worn out or damaged O O O
Faulty front axle, etc.
Front axle deformed O

Knuckle arm, tie rod arm, knuckle, etc. im-
O O
properly tightened
Front spring U-bolt, nut, etc. loose O Gr33
King pin bearing poorly greased O O
King pin bearing worn out or damaged O O O
Front axle parts overtightened O
Gr26
Steering angle incorrectly adjusted O O
Mounted parts, connections loose O
Knuckle stopper bolt improperly adjusted O O
Oil pump body faulty O
O-ring, oil seal faulty O
Bolt improperly tightened O
Maximum generated oil pressure insuffi-
Faulty oil pump
O O
cient
Oil line crushed or clogged O O O
Air caught in oil pump O O O
Oil pump interior seized O O O O O
Mounting bolt and nut loose O
Pump body faulty O O O
Valve malfunctioning O O
37-9
TROUBLESHOOTING
Symptoms




Reference Gr

Steering shimmy
Oil leakage
unstable
Possible causes
Faulty power
Bleeding insufficient O
cylinder
Rod bent, piston hitching or worn O
Ball stud loose O O O

Load excessive forward of load-carrying
O
platform
Load excessive rearward of load-carrying
O
platform
Load excessive on one side of loading
O
bed
Difference excessive in wheelbase be-
O
tween left and right
Propeller shaft runout excessive O Gr25
Front axle bent O Gr26
Other abnormalities
Rear axle housing bent O

Final drive gear and final drive pinion Gr27
O
damaged or improperly engaged
Tire pressure insufficient O
Tire pressure excessive O
Difference excessive in degree of wear
O
between left and right tires
Gr31
Left and right tires different in outer diam-
O
eter
Front tire radial and lateral runout, static
O
and dynamic balance incorrect
Braking force unbalanced O Gr35
Oil leakage from oil tank due to filling be-
O
yond capacity
Oil leakage from oil tank due to air caught
O
inside
37-10
37
M E M O
37-11
1. Oil Leakage and Replacement of Power Steering Oil
Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Within grid
Automatic transmission fluid
– Power steering oil tank marked range on
(DEXRON II or DEXRON III type)
oil level gauge
1.1 Oil leakage

• Check the power steering oil tank, power steering oil pump,
power steering booster, power cylinder, and hose and pipe con-
nections for oil leak. Check also the hoses for blister due to dete-
rioration, damage and crack.
• If any oil leak is found, tighten the connection or replace the
faulty parts.
1.2 Replacement
[Draining]
• Jack up the front wheels.
• Before disconnecting the feed and return pipes, clean their con-
nections and nearby areas to prevent dust and other foreign
matter from entering the pipes and steering booster.
• Disconnect feed and return pipes connected to the power steer-
ing booster.
• Repeatedly turn the steering wheel fully left and right to drain the
hydraulic fluid from the power steering booster, and then con-
nect the feed pipe and return pipe.
[Filling]
• Pour fluid into the power steering oil tank up to the bottom of the
filler cap.
• Bleed the power steering system of air.
37-12
37
2. Bleeding of Power Steering System

Within grid
– Power steering oil tank marked range on
oil level gauge
• Pour fluid to the power steering oil tank up to the bottom of the
filler cap.
• With the engine stopped, jack up the front wheels.
• Repeatedly turn the steering wheel fully left and right. When the
fluid level has dropped, add fluid enough to maintain the fluid
level within the specified range.
NOTE
• When checking the level of the fluid with the level gauge, do
not screw in the filler cap but simply put it on the filler port.
• Start the engine to idle.

• When the fluid level has dropped, stop the engine and add fluid.
• Restart the engine. While checking for a drop in the fluid level,
repeatedly replenish the hydraulic fluid until the fluid level is sta-
bilized.
CAUTION
• To avoid seizure of the power steering oil pump, do not
keep the steering wheel turned fully to left or right for more
than 10 seconds when the engine is running.
• If there is any abnormal noise or a fluid level fluctuation, air

should be still trapped in the power steering system. Turn the
steering wheel several times to raise the fluid temperature to ap-
proximately 60 to 80°C.
• Stop the engine and wait for approximately five minutes.
• Lower the front wheels and turn the steering wheel several
times. If there is no noise or fluid level fluctuation, the bleeding of
the power steering system is completed.
• When air bleeding is completed, check the fluid level in the oil
tank, and pipe and hose connections for fluid leaks.
37-13
3. Performance Verification Test of Power Steering System
Service standards
Location Maintenance item Standard value Limit Remedy
2}
Power steering system fluid pressure (with hands off 490 kPa {5 kgf/cm or
– – Repair*
steering wheel) less
0
13.73 –0.69 MPa
Except FS
{140 –70 kgf/cm2}
– Relief set pressure – Repair*
12.3 +0.5
–0.2 MPa
FS 2
{125 +5
–2 kgf/cm }
*: Check the power steering booster and hydraulic circuit for clogging.
• Perform the tests with the following measuring conditions to ver-

ify normal operation of the power steering booster and power
steering oil pump.
• Install oil pressure gauge capable of measuring upward of 14.7
MPa {150 kgf/cm2} and stop valve between power steering oil
pump and power steering booster, then bleed air.
• Start engine to idle.
• Turn steering wheel left and right several times to raise fluid tem-
perature up to 50 to 60°C.
• With the engine idling, fully open stop valve.
CAUTION
• To avoid seizure of the power steering oil pump, never
close the stop valve for more than 10 seconds.
Test item Test procedure Judging standard

Verification of smooth Smooth operation
• Jack up front wheels and turn steering wheel fully left and right.
operation throughout test
Measurement of fluid
Specified standard
pressure in power steering • Measure fluid pressure with hands off steering wheel.
value
system
• Measure maximum fluid pressure with the stop valve tightened at engine
Measurement of relief set Specified standard
idle.
pressure value
• Do not close stop valve for longer than 10 seconds.
37-14
37
4. Steering Wheel Play
Service standards (Unit: mm)

– Steering wheel play 15 to 35 – Adjust
• With the vehicle placed straight forward, start the engine and
gently turn the steering wheel right and left to measure its pe-
ripheral play.
• If the play deviates from the standard value, check tightening
points and backlash of the power steering booster.
5. Steering Column Looseness

• Push and pull the steering wheel by hand to check the steering
column for looseness.
• With the steering column tilted all the way forward, pull the steer-
ing wheel backward and check the steering column for loose-
ness.
• If the steering column is loose, adjust the tilting and telescoping
lever.
6. Inspection of Rods and Arms for Looseness

• Check the rods and arms of drag link,
connecting link, pitman arm, slave le-
ver for damage and looseness.
• If any abnormality is found, replace the
faulty parts or tighten the parts to the
specified torque.
37-15
7. Inspection of Power Steering System Mounts for Looseness
• Check the mounting sections of power steering oil tank, power
steering oil pump, power steering booster and power cylinder for
looseness.
• Check the connections of hose and pipe for looseness.
• If any looseness is found, tighten the loose parts to the specified
torque.
8. Play in Drag Link, Power Cylinder End and Tie Rod Ends

Play at ball joint of drag link, power cylinder end and tie
– 0 to 0.4 0.8 Replace
rod ends (displacement)
• With the engine shut down, raise the front axle with a jack until
both front wheels are clear of the ground.
8.1 Drag link and power cylinder ends

• Turn the steering wheel to the right to keep the knuckle stopper
bolt of the right wheel in contact with the front axle.
• Set a dial indicator on the drag link or power cylinder end as

shown in the illustration. Apply the dial indicator’s probe perpen-
dicularly against the ball joint and in line with the stud axis.
• Zero-adjust the dial indicator in the following method.
• Lightly turn the steering wheel to the right from the point where
the knuckle stopper bolt is in contact with the front axle and then
release the steering wheel. Repeat this operation a few times
and check that the dial indicator reading returns to zero each
time the steering wheel is released.
NOTE
• Release the steering wheel slowly.
37-16
37
• After completing zero adjustment, turn the steering wheel to the
right by 36 degrees (or through 6 bosses on the inner periphery
of the steering wheel) and read the resulting displacement on
the dial indicator.
• If the measurement value exceeds the limit, replace the drag link
or power cylinder end. If the measurement value is more than
the standard value and less than the limit, remove the drag link
or power cylinder end and inspect it. (See “POWER STEERING
BOOSTER AND DRAG LINK” or “POWER CYLINDER”)
• Perform the above measurement for the front and rear ends of
the 2nd drag link, 3rd drag link and power cylinder end (2 places
in total).
8.2 Tie rod ends

• Install a knuckle stopper bolt on the front side of the left wheel.
• Adjust the knuckle stopper bolt such that it touches the front axle
before the knuckle stopper bolt on the right wheel does.
• Set the dial indicator on the tie rod as shown in the illustration.
• Apply the dial indicator’s probe in line with the axis of the ball
joint.
• Zero-adjust the dial indicator in the following method.
• Lightly turn the steering wheel to the right from the point where
the knuckle stopper bolt comes in contact with the front axle and
then release the steering wheel. Repeat this operation a few
times and check that the dial indicator reading returns to zero
each time the steering wheel is released.
NOTE
• Release the steering wheel slowly.
• After completing zero adjustment, turn the steering wheel to the

right by 36 degrees (or through 6 bosses on the inner periphery
of the steering wheel) and read the resulting displacement on
the dial indicator.
• If the measurement value exceeds the limit, replace the tie rod
end. If the measurement value is more than the standard value
and less than the limit, remove the tie rod end and inspect it.
(See Gr26.)
• Perform the above measurement for the left and right ends of
the tie rod (2 places in total).
• After necessary adjustment, remove the knuckle stopper bolt
from the front side of the left wheel.
9. Inspection of Dust Cover of Drag Link, Connecting Link Rod, Power Cylinder
End and Tie Rod End
• Check that there are no wear, cracks or damage. These abnormalities can cause water to enter the ball joint, re-
sulting in premature wear.
• If wear, crack, or damage is present, inspect traces of water entry and occurrence of rust in the ball joint. If any ab-
normality is found, replace the drag link, connecting link rod, power cylinder end or tie rod end. If no abnormality is
found, replace the dust cover and reapply grease. (See later section or Gr26.)
37-17
STEERING COLUMN
37-18
37
Removal sequence
1 Horn pad 9 Starter switch 17 Support
2 Steering wheel 10 Harness cover 18 Dust cover
3 Shaft rear cover 11 Bracket clamp <Tractor> 19 Steering column
4 Shaft front cover 12 Set pin <Tractor> (See later section.)
5 Grommet 13 Trailer brake lever <Tractor>
6
7
Combination switch
Twist-off bolt
14
15
Ring spring <Tractor>
Lever bracket <Tractor>
*a:: Power steering booster
Non-reusable parts
8 Clamp 16 Universal joint <Tractor>
Installation sequence
Follow the removal sequence in reverse.
• After installation, check the steering column for looseness. (See “ON-VEHICLE INSPECTION AND ADJUST-
MENT”.)
Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
Screw (horn pad mounting) 3.92 {0.4} –
Nut (steering wheel mounting) 68 to 78 {6.9 to 8.0} –
Screw (combination switch mounting) 2.5 ± 0.5 {0.25 ± 0.05} –
Twist-off bolt (starter switch mounting) 13 to 15 {1.3 to 1.5} –
Bolt (steering column mounting) 17 to 26 {1.7 to 2.6} –
Nut (steering column mounting) 9 to 14 {0.9 to 1.4} –
Nut (steering column to power steering booster mounting) 51.45 ± 2.45 {5.25 ± 0.25} –

Wheel bearing grease
Rubbing surfaces of trailer brake lever As required
[NLGI No. 2 (Li soap)]
Special tools (Unit: mm)

Mark Tool name and shape Part No. Application
Steering wheel puller

MH062421 Removal of steering wheel
A B
M10 × 1.25 M14 × 1.5
37-19
STEERING COLUMN
Work before removal
Alignment mark: Steering column and power steering
booster
• Provide alignment marks on the steering column and power
steering booster.
Removal procedure
Removal: Steering wheel
• After removing the steering wheel mounting nuts, be sure to pro-
vide alignment marks on the steering wheel and steering shaft.
Removal: Starter switch

• Drill a hole of 5.5 to 6 mm in diameter to a depth of 10 to 15 mm
in the twist-off bolt.
• Using the drilled hole, screw the screw extractor counterclock-
wise into the twist-off bolt and remove it.
37-20
37
Installation procedure
Installation: Starter switch
• Install the starter switch using new twist-off bolts.
• Twist off the bolt head of the twist-off bolt.
• Check for operation of the steering lock function of the starter
switch.
Installation: Steering wheel

• Align the steering wheel holes with the cancel cam protrusions
of the combination switch to install the steering wheel.
Work after installation

Inspection: Noise from steering wheel
• Lightly turn the steering wheel left and right and check for noise
and other abnormalities.
• If any abnormality is found, disassemble the steering wheel, re-
move the cause and reinstall.
37-21
STEERING COLUMN
Disassembly sequence
1 Lock lever 7 Snap ring 13 Grease nipple
2 Nut 8 Steering column 14 Steering joint
3 Washer and stopper set 9 Stopper 15 Steering shaft bracket
4 Self-locking nut 10 Bearing spacer
5 Return spring 11 Stopper : Non-reusable parts
6 Bushing 12 Snap ring
Assembly sequence
Follow the disassembly sequence in reverse.
37-22
37
Bolt (lock lever mounting)
9 to 14 {0.9 to 1.4} –
Self-locking nut (steering column mounting)
Nut (steering column mounting) 29 ± 2 {3 ± 0.2} –
Grease nipple 3 to 5 {0.3 to 0.5} –

Surface of steering shaft bracket rubbing against steering
column Wheel bearing grease
As required
Grease through grease nipple
Installation: Steering joint
• When the steering joint has been separated at the splined por-
tion, reconnect it so that the yokes of the upper and lower joints
will face in the same direction (arrows A).
Installation: Lock lever

• Install the lock lever so that its operating range conforms to the
angle indicated in the illustration.
37-23
POWER STEERING BOOSTER AND DRUG LINK
Removal sequence
1 Drag link (See later section.) 5 Power steering booster (See later section.)
2 Feed pipe 6 Power steering booster bracket
3 Return pipe
4 Oil pipe <FS> : Non-reusable parts
CAUTION
• When removing the drag link, do not deform or damage the dust cover.
• When removing the oil pipe, clean the port area to prevent ingress of dust and dirt.
37-24
37
Installation sequence
Follow the removal sequence in reverse.

Except FS 353 ± 88 {36.0 ± 9.0}
Nut (drag link mounting) –
FS 190 ± 47.5 {19.4 ± 4.85}
Nut (power steering booster mounting) 270 ± 34 {27.5 ± 3.5} Wet
Nut (power steering booster bracket mounting) 255 to 343 {26.0 to 35.0} –
37-25
POWER STEERING BOOSTER AND DRUG LINK
Drag Link
1 Dust cover
2 Drag link
: Non-reusable parts
NOTE
• The drag link is designed as an in-
tegral part. Do not try to disassem-
ble it.
• Do not remove the dust cover un-
less it is in an abnormal condition.
Assembly sequence
Follow the disassembly sequence in re-
verse.
Service Standards (Unit: mm)

Under load of 560 N
{57 kgf} <Except FS>
Looseness – 0.7 Replace
Under load of 500 N
2 Ball joint of drag link {51 kgf} <FS>
0.5 to 12 N·m
Turning torque {0.05 to – Replace
1.2 kgf·m}

Lip area of dust cover As required
Molybdenum disulfide grease
Except FS 33 to 34 g
Inside of dust cover [NLGI No.2 (Li soap)]
FS 19 to 20 g
37-26
37
Dust cover installer

<Except FS>
MH062800
<FS>
MH061827
A B C
Except FS φ74 φ63.9
100
FS φ65 φ51
Installation of dust cover
End holder
<Except FS>
MH062730
<FS>
MH061829
A B C D
Except FS φ70 φ61.7
φ35 25
FS φ64 φ55.7
Inspection procedure
Inspection: Ball joint of drag link
(1) Looseness
• Secure the drag link in a vise.
CAUTION
• Do not damage the dust cover when securing the drag link
in a vise.
• If the measured value exceeds the limit when the specified load
(push-in) is applied, replace the drag link.
(2) Turning torque

• Install a nut on the ball joint of the drag link.
• Install a socket, adapter and torque wrench, and measure the
turning torque.
• If the measured value is out of the standard value, replace the
drag link.
(3) Dust cover

• Check that there are no wear, cracks, and damage. These ab-
normalities can cause water to enter the ball joint, resulting in
premature wear.
• If wear, crack or damage is present, inspect traces of water entry
and occurrence of rust in the ball joint. If any abnormality is
found, replace the drag link. If no abnormality is found, replace
the dust cover and reapply grease.
37-27
POWER STEERING BOOSTER AND DRAG LINK
Installation: Dust cover
• Fill the inside A and coat the lip of the dust cover with grease.
• Hold the dust cover between and and compress them
with a vise or other appropriate means until the reinforcement
ring closely touches the drag link.
37-28
37
M E M O
37-29
Power Steering Booster
37-30
37
1 Pitman arm 16 O-ring 31 Bearing cage
2 Dust cover 17 Piston 32 Seal ring
3 Needle bearing 18 Ball bearing 33 Rotor
4 Y-packing 19 Oil seal 34 Stub shaft and worm shaft
5 Backup ring 20 Adjusting plug 35 O-ring
6 O-ring 21 Wave washer 36 Oil seal
7 Side cover 22 O-ring 37 Needle bearing
8 Retainer 23 Seal ring 38 Y-packing
9 Adjusting screw 24 O-ring 39 Backup ring
10 Sector shaft 25 O-ring 40 Plug
11 Dust cover 26 Connector 41 Body
12 Ball tube clip 27 Plug
13 Ball tube 28 Valve housing : Non-reusable parts
14 Steel ball 29 Side race
15 Seal ring 30 Steel ball
NOTE
• Do not remove the parts marked with unless defects are evident.
• Prepare a receiver when disassembling the parts that contain steel balls.
Assembly sequence
Repair kit: Power steering booster kit

Backlash between sector shaft and piston (measure at
– 0.05 to 0.35 – Adjust
tip of pitman arm)
9, 10 Axial play between adjusting screw and sector shaft 0.01 to 0.10 0.2 Replace
Adjusting screw Except FS φ52.975 φ52.875
Sector shaft outside
10 FS φ47.975 φ47.875 Replace
side diameter
Pitman arm side φ57.975 φ57.875
17, 34 Looseness in piston and stub shaft in radial direction – 0.5 Replace
Piston outside diameter-to-body inside diameter clear-
17, 41 0.11 0.16 Replace
ance

Lock nut (pitman arm mounting) 417 ± 25 {42.5 ± 2.5} –
Bolt (side cover mounting) 73.6 to 83.4 {7.5 to 8.5} –
Nut (adjusting screw tightening)
117.7 to 127.5 {12 to 13} –
Bolt (valve housing tightening)
Plug (body, valve housing) 8.9 to 12.7 {0.9 to 1.3} Sealant
Screw (ball tube clip mounting) 4.41 to 5.39 {0.4 to 0.5} –
Adjusting plug 226 to 245 {23 to 25} –
Connector 63 to 94 {6.4 to 9.6} –
37-31
Mating surfaces of nut and side cover
Hermetic seal 101Y or
Adjusting screw thread As required
ThreeBond 1102
Outer surfaces of adjusting plug
Inner surfaces of backup ring
Fill in inner surfaces of Y-packing
Fill in inner surfaces of retainer Multipurpose grease
As required
Fill in mating surfaces with sector shaft of adjusting screw [NLGI No.2 (Li soap)]
Fill inside ball tube
Fill in inner surfaces of oil seal
Wind around plug thread Seal tape As required

Pitman arm puller
A: Body
B: Bolt
MC064114
C D Removal of pitman arm
*910-00184
59 φ100
MC811971 Formation of backup ring and installa-

Insert tool assembly
*910-11001 tion of oil seal
Insert tool
MC811973
Formation of backup ring
*910-21704
A B C D
φ58 φ25 53.5 φ33
Needle
MC811948
A B Removal of O-ring and seal ring
*910-21200
120 φ3
Bar
MC811955
A B For turning of retainer
*910-22811
φ16.5 57
*: Unisia JKC Steering Systems part numbers
37-32
37
Squeeze tool
MC811950
For caulking of retainer
*910-21801
A B C D E F
5 8 18 φ30 6 160
Insert tool
MC064116
For forming backup ring
*910-21732
A B C D
φ53 φ25 53.5 φ33
Insert tool
MC064115
For forming seal ring of piston
*910-21731
A B C D
φ118 φ110 50 φ100
Attachment assembly MC811969

(A: Adapter) *910-10671
(B: Bolt (pin)) (A:
Fixture of valve housing
*910-23583)
C (B:
*910-23194)
φ158
Wrench assembly
MC811970 Removal and installation of adjusting
A B
*910-10743 plug
φ70 φ62
Press-fit tool
MC811972
Installation of oil seal
*910-20404
A B C D
φ45 φ40 φ24.6 27.5
37-33
MC811968 Assembly of side race, steel balls and

Tool assembly
*910-10611 bearing cage
Guide assembly MC090148 Assembly of side race, steel ball and

*910-23033 bearing cage
A B C D
φ93.5 φ77.5 φ88 30
Insert tool
MC811975
A B C Formation of seal ring
*910-22772
45 φ47.4 φ48
Work before removal

Preparatory work: Setting of pitman arm at neutral position
• Move the pitman arm and set the V-groove slit of the sector shaft
at the center of the body to place gear engagement in neutral
position.
Removal procedure
Removal: Pitman arm
37-34
37
Removal: Sector shaft and side cover
• Make sure that the piston is at the neutral position (the V-groove
slit of the end face of the sector shaft is in the center of the
body).
• Tap the end face of the sector shaft to remove the sector shaft
and side cover.
Removal: Side cover

• Remove the side cover by tightening the adjusting screw.
Inspection: Axial play between adjusting screw and sector

shaft
• Measure the axial play between adjusting screw and sector shaft
after removing the side cover.
[Inspection]
• Hold the sector shaft with a vise.
CAUTION
• When pinching the sector shaft with a vise, be sure to apply
cloth to it to prevent damage.
• Measure the axial play between adjusting screw and sector

shaft.
• If the measurement value exceeds the limit, replace the retainer.
Replacement of retainer
[Removal]
• Raise the caulked areas (two locations) of the retainer with a
chisel.
37-35
[Installation]
• Fill the adjusting screw mounting hole of the sector shaft with
grease.
• Install the adjusting screw on the sector shaft.
• Install the retainer on the sector shaft using .
• After tightening, return the retainer by 180° once. Then, retighten
it to the torque of 39 N·m {4 kgf·m} and return it by 20°.
• Make sure that the adjusting screw turns smoothly.
• Caulk caulked locations (two) of the retainer using .
Removal: Worm shaft and valve housing

• Before removing worm shaft and valve housing, return the ad-
justing valve by approximately 180° using to loosen.
CAUTION
• Only loosen the adjusting plug because removal of it may
cause the bearing in the valve housing to jump out.
• Remove the worm shaft and valve housing from the body.
CAUTION
• Take care not to allow the ball of the worm shaft and valve
housing to jump out.
• Do not damage the inside of the body and the piston.
Removal: Piston
• Hold the worm shaft and valve housing with the piston facing
downward, and turn the stub shaft and worm shaft to remove the
piston.
CAUTION
• Steel balls assembled into the race of the piston and stub
shaft and worm shaft fall into the piston. Take care not to
tumble the piston.
37-36
37
Removal: Ball tube and steel ball
• After removing the steel balls from the piston, remove the ball
tube clip and pinch the ball tube with fingers and lightly move it
to remove from the piston.
CAUTION
• Take care not to lose steel balls (32 pieces).
Removal: Stub shaft and worm shaft

• Press out the piston assembled side of the stub shaft and worm
shaft to remove from the valve housing.
CAUTION
• The side race, steel balls and bearing cage come apart. Pre-
pare a receiver not to lose them.
Inspection: Looseness in piston and stub shaft and worm
shaft
• Measure looseness B of the worm shaft and valve housing in the
radial direction when a force of 49 N {5 kgf} is applied to illustrat-
ed area A.
• If the measured value exceeds the limit, replace the defective
part(s).
Installation: Backup ring and Y-packing
• Fill the Y-packing groove with grease and install it in the illustrat-
ed direction.
• The backup ring can be easily installed in the illustrated shape.
After installation, form it with and .
37-37
Installation: Oil seal
• Install the oil seal on the body in the illustrated direction.
Installation: Seal ring

• Install the seal ring on the rotor.
• Form the seal ring with .
Installation: Rotor
• Install the notch of the rotor so that it is in alignment with the lo-
cating pin of the stub shaft and worm shaft.
Installation: Side race, steel ball and bearing cage

• Assemble onto and install the stub shaft and worm
shaft in the illustrated direction.
• Install the bearing cage and steel balls onto the stub shaft and
worm shaft.
• Hold by hand and slide downward to set the steel

balls in place.
37-38
37
• Install the side race on the steel balls and bearing cage.
Installation: Seal ring and O-ring

• Install the seal ring and O-ring on the valve housing.
• Form the seal ring with .

• Install the oil seal on the adjusting plug in the illustrated direc-
tion.
Installation: Stub shaft and worm shaft

• Install the valve housing on the stub shaft and worm shaft and
secure it with adjusting plugs.
CAUTION
• Take care not to damage the seal ring with the ball race of
the stub shaft and worm shaft.
• Secure the valve housing to a vise using .

• Tighten the adjusting plug to the specified torque with , and
then loosen it by approximately 180°.
37-39
Installation: Seal ring and O-ring
• Install the seal ring and O-ring on the outer surface groove of the
piston and form the seal ring with .
Installation: Ball tube

• Fill the inside of the ball tube with grease, place 10 to 11 steel
balls, and lay another ball tube on top of the ball tube.
• Place the piston on a flat bench and align the assembled worm
shaft and valve housing with the ball race position of the piston.
While turning the stub shaft and worm shaft, drop steel balls
from the ball tube hole.
CAUTION
• Take care that steel balls may fall off the ball race if the
worm shaft and valve housing is pulled out to the end face
position.
Installation: Worm shaft and valve housing

• Face the gear of the worm shaft and valve housing in the illus-
trated direction so that it can be engaged with the sector shaft.
• Install the gear on the body while lightly holding down the gear
by hand to prevent it from turning. Align the worm shaft and
valve housing with the oil passage holes of the body to install.
CAUTION
• Take care not to damage the piston seal ring and the inside
of the body.
Installation: Backup ring and Y-packing

• Install the Y-packing on the side cover in the illustrated direction.
• After installing the backup ring, fill the Y-packing groove with
grease.
37-40
37
• After installing the needle bearing, form the bend of the backup
ring using and .
Installation: Sector shaft

• Set the V-groove slit of the sector shaft of the sector shaft and
side cover at the center of the body, and install the sector shaft
so that the gear of the piston is engaged with the gear of the
sector shaft at their respective center.
CAUTION
• Tape the sector shaft thread to install to prevent the Y-pack-
ing from being damaged by the sector shaft thread.
Tightening: Adjusting plug

• After tightening the side cover mounting bolts to the specified
torque, retighten the adjusting plugs to the specified torque us-
ing .
Installation: Pitman arm

• Set V-groove slit A of the sector shaft at the center of the body,
and align V-groove slit B of the pitman arm or missing tooth posi-
tion C of serration with slit A.
• After installing the pitman arm, move it by hand to make sure
that the piston can move over its full stroke range smoothly.
• If movement is deficient, remove and reinstall the power steering
booster.
Adjustment after installation

Adjustment: Backlash between sector shaft and piston
• Measure runout of the tip of the pitman arm with a dial gauge
with gear engagement placed in neutral position. Adjust using
the adjusting screw so that the measurement is within the stan-
dard value.
Measured load: 20 N {2.0 kgf}
37-41
• After adjusting backlash, apply sealant to the adjusting screw
threads. Tighten the nut to the specified torque while securing
the adjusting screw with a screwdriver to prevent it from turning.
37-42
37
M E M O
37-43
POWER STEERING OIL PUMP <UNISIA JKC STEERING SYSTEMS Product>
1 Hose connector 11 Rotor 21 Retaining ring
2 O-ring 12 Cam 22 Ball bearing
3 Plug 13 Side plate 23 Retaining ring
4 O-ring 14 Straight pin 24 Drive shaft
5 Flow control valve 15 O-ring 25 Retaining ring
6 Flow control spring 16 O-ring 26 Oil seal
7 Rear body 17 Lock washer 27 Front body
8 Pressure plate 18 Oil pump gear
9 Cartridge assembly 19 Retaining ring : Non-reusable parts
10 Vane 20 Key
NOTE
• Do not attempt to disassemble the flow control valve because it is of unit construction.
• Do not remove the ball bearing and oil seal unless their removal is absolutely necessary.
• See Gr11 for removal and installation of the power steering oil pump.
Assembly sequence
Repair kit: Seal kit, cartridge assembly kit
37-44
37
Service standards
Air leakage of flow control valve
5 0 dm3 {0 L} – Replace
(applying air pressure 390 to 490 kPa {4 to 5 kgf/cm2})

Bolt (hose connector mounting) 17.7 to 24.5 {1.8 to 2.5} –
Plug
49.0 to 58.8 {5 to 6} –
Bolt (rear body mounting)
Screw (pressure plate mounting) 5.9 to 8.8 {0.6 to 0.9} –
Nut (gear mounting) 80 {8} –

Mating surfaces of plug and O-ring Automatic transmission fluid
As required
O-ring (DEXRON II or DEXRON III type)
Special tools
Removal and installation of retaining
Pliers *910-22570
ring
Removal and installation of retaining
Pliers *910-22580
ring
Press-fit tool *910-22972 Removal and installation of bearing
Stick *910-21632 Removal of oil seal
Press-fit tool *910-22974 Installation of oil seal
* Unisia JKC Steering Systems part numbers
Removal procedure
Removal: Cartridge assembly
• Put alignment marks across the pressure plate, cartridge as-
sembly and side plate outside surfaces.
• Remove the screws, then remove the pressure plate, cartridge
assembly, side plate and straight pins as a single unit from the
front body.
Removal: Retaining ring
37-45
Removal: Ball bearing

• Remove the ball bearing toward the drive side (gear side) of the
drive shaft.
Removal: Oil seal
Inspection: Flow control valve and rear body
(1) Air leakage of flow control valve
• Check if there is not a foreign body in the filter at port B. If a for-
eign body is found, remove it.
• Apply the specified air pressure to port A.
• Check if there is not air leakage from port B.
• If any abnormality is found, replace the flow control valve.
(2) Inspection of aspect of flow control valve and rear body

• Check if there is not scratch, wear or edge on the sliding surface
of the rear body and the flow control valve by watching and
touching.
• Insert the flow control valve in the illustrated direction and check
if the flow control valve falls into the rear body smoothly by its
weight without catching on the body.
• If any abnormality is found, replace the flow control valve or rear
body.
37-46
37
Inspection: Pressure plate
• Check if there is not stepped wear or scratch that causes finger-
nail to catch on the sliding surface of the rotor and vane. If any
abnormality is found, replace the pressure plate.
Inspection: Vanes and rotor

• Check if there is not scratch or wear on the sliding surface of the
pressure plate and the side plate by watching and touching.
• Check if there is not scratch on the slit surface of the rotor and
the vanes by watching and touching.
• Install each vane on the rotor with its rounded end facing out,
and check all vanes for smooth movement.
• Apply light to the rotor with installing the vanes and check if
there is not light leakage from the slit between the vane and ro-
tor.
• If any abnormality is found, replace the cartridge assembly.
Inspection: Side plate

nail to catch on the sliding surface of the rotor and vane. If any
abnormality is found, replace the side cover.
• Install the oil seal on the front body in the illustrated direction.
37-47
Installation: Ball bearing
• To install the ball bearing, follow the removal procedure in re-
verse. (See “ Removal: Ball bearing”.)
Installation: Retaining ring
Installation: Drive shaft

• When installing the drive shaft into the front body, if it is not in-
serted into the normal position by hand, lightly tap the shaft to in-
stall.
Installation: Lock washer

• After tightening the nut, bend the lock washer against one of the
flats of the nut.
37-48
37
Installation: Vanes
• Install each vane on the rotor with its rounded end facing out.
Installation: Rotor
• Install the rotor to the cam with facing the circle groove to the
pressure plate side.
Installation: Cartridge assembly

• Install the straight pins in the front body.
• Install the side plate, cartridge assembly and pressure plate
while aligning the marks that were put on them at the time of re-
moval and tighten the screws to the specified torque.
• When installing a new cartridge assembly, install it with facing
the circle groove of the rotor to the pressure plate side.
NOTE
• Insert the straight pins in the correct holes in every part.
Installation: Flow control valve

• Install the flow control valve to the rear body in the illustrated di-
rection.
37-49
POWER STEERING OIL PUMP <KYB Product>
1 Suction connector 11 Side plate B 21 Key
2 O-ring 12 Cartridge assembly 22 Retaining ring
3 Plug 13 Vane 23 Ball bearing
4 O-ring 14 Rotor 24 Shaft
5 Relief valve 15 Cam 25 Oil seal
6 Flow control spring 16 Side plate A 26 Connector
7 Retaining ring 17 Pin 27 O-ring
8 Cover 18 Lock washer 28 Body
9 O-ring 19 Oil pump gear
10 Spring 20 Retaining ring : Non-reusable parts
NOTE
• Do not attempt to disassemble the relief valve because it is of unit construction.
• Do not remove the ball bearing and oil seal unless their removal is absolutely necessary.
• See Gr11 for removal and installation of the power steering oil pump.
Assembly sequence
Repair kit: Seal kit
37-50
37
Air leakage of relief valve
5 0 dm3 {0 L} – Replace
(applying air pressure 390 to 490 kPa {4 to 5 kgf/cm2})
5, 28 Relief valve-to-body clearance 0.017 0.03 Replace

Bolt (suction connector mounting) 22 to 25 {2.2 to 2.6} –
Plug 69 to 98.1 {7 to 10} –
Nut (oil pump gear mounting) 78 to 98 {8 to 10} –
Connector 58 to 78 {6 to 8} –

Mating surfaces of plug and O-ring
Mating surfaces of connector and O-ring As required
O-ring

Press-fit tool
MC090136 Installation of shaft assembly
A B C D E F G H
φ61 φ52 φ26 55 40 20 φ40 10
Guide tool A
MC090137
A B C D E F G
φ23 φ22 φ25 φ25.4 36 18 12.8
Installation of retaining ring
Guide tool B
MC090138
A B C D E F
φ26 φ24.5 φ23 65 5 5
37-51
Guide tool C
MC090139 Installation of retaining ring
A B C D
φ54 φ26.1 φ29 5
Press-fit tool
MC090134 Installation of ball bearing
A B C D E F G H I
φ70 φ62.2 φ35 φ27 98 85 25 φ50 8
Removal procedure
• Hold down the cover with a hand press or other appropriate
means to prevent it from jumping out by the tension of the
spring.
Inspection: Relief valve and body
(1) Air leakage of relief valve
• Block the port A of the relief valve by the finger.
• Apply the specified air pressure to port B.
• Check if there is not air leakage from port C.
• If any abnormality is found, replace the relief valve.
(2) Inspection of aspect of relief valve and body

• Check if there is not scratch, wear or edge on the sliding surface
of the body and the relief valve by watching and touching.
• If any abnormality is found, replace the relief valve or body.
(3) Relief valve-to-body clearance

• If the measurement exceeds the limit, replace the relief valve
and body.
37-52
37
Inspection: Drive shaft
nail to catch on the sliding surface of the drive shaft and oil seal.
• If any abnormality is found, replace the drive shaft.
Inspection: Vanes and rotor

• Check if there is not scratch or wear on the sliding surface of the
side plates by watching and touching.
• Check if there is not scratch on the slit surface of the rotor and
the vanes by watching and touching.
• Install each vane on the rotor with its rounded end facing out,
and check all vanes for smooth movement.
• If any abnormality is found, replace the cartridge assembly.
Inspection: Side plate

nail to catch on the sliding surface of the rotor and vane.
• If any abnormality is found, replace the side plate.
37-53
• Install the oil seal into the body using a tool of the dimensions in-
dicated in the illustration.
Installation: Ball bearing

• Install on the drive shaft, and set the retaining ring on the
tool.
• Install on . By using them as a guide, slide the retain-

ing ring down to the ball bearing with .
Installation: Drive shaft
37-54
37
Installation: Lock washer
• After tightening the nut, bend the lock washer against one of the
flats of the nut.
Installation: Side plates

• For both side plates A and B, insert the relief-valve-side pin in
the slot (not the round hole).
Installation: Vanes
• Install each vane on the rotor with its rounded end facing out.
Installation: Rotor
• Install the rotor in the cam with the chamfered end toward the
body.
Installation: Cartridge assembly

• Insert the relief-valve-side knock pin in the slot (not the round
hole) of the cartridge assembly.
37-55
Installation: Cover
• Before installation, position the cover correctly so as not to let its
two projections interfere with the ports in the side plate.

• Install the retaining ring in the groove of the body with its end
gap next to the disassembling hole.
37-56
37
M E M O
37-57
POWER STEERING OIL TANK
1 Hose 7 Spring 13 O-ring
2 Return pipe 8 Retainer 14 Tank body
3 Oil filler cap 9 Return filter 15 Bracket A
4 Oil strainer 10 Elbow (supply) 16 Bracket B
5 Plate 11 O-ring
6 Packing 12 Elbow (return) : Non-reusable parts
Assembly sequence

Nut (elbow mounting) 69 to 82 {7.0 to 8.4} –
Clamp 35.0 ± 5 {3.6 ± 0.5} –
Return pipe 98 {10} –

O-ring As required
37-58
37
Installation: Elbow
• Install the elbow to the tank body in the illustrated direction.
Installation: Return pipe

• When the return pipe and elbow have been replaced with a new
one, install them by tightening the connection (marked with )
to the specified torque, loosen once, and then retighten to the
specified torque.
37-59
CONNECTING LINK ROD <FS>
37-60
37
1 2nd drag link (A) 20 Ball bushing 38 Washer
2 Grease nipple 21 Bushing 39 Grease nipple
3 Lock sheet 22 Bushing 40 Straight joint
4 Sub cylinder end pin 23 Slave lever 41 Bushing
5 Side washer 24 Grease nipple 42 Bushing
6 Side washer 25 Lock sheet 43 Slave lever
7 1st drag link (A) 26 Connecting link pin 44 Slave lever bracket
8 Grease nipple 27 Side washer 45 Slave lever bracket
9 Lock sheet 28 Side washer 46 Power cylinder bracket
10 Connecting link pin 29 Connecting link end
11 Side washer 30 Connecting link rod
*a: Power steering booster
12 Side washer 31 3rd drag link (A)
*b: Pitman arm
13 Slave lever shaft 32 Power cylinder hose
*c: Front 1st axle (See Gr26.)
14 Disc spring 33 O-ring
*d: Front 2nd axle (See Gr26.)
15 Washer 34 Power cylinder
16 Washer (See later section.) : Non-reusable parts
17 Grease nipple 35 Slave lever shaft
18 Straight joint 36 Disc spring A: See “POWER STEERING
19 Circlip 37 Washer BOOSTER AND DRAG LINK”.
• When removing the power cylinder hose, clean the connecting area to prevent ingress of dust and dirt.
• Do not remove slave lever bracket unless it is faulty.
Assembly sequence

10, 21,
Clearance between connecting link pin and bushing 0.03 to 0.13 0.4 Replace
26, 41
13, 22,
Clearance between slave lever shaft and bushing 0.015 to 0.111 0.4 Replace
35, 42
13, 35, Clearance between slave lever shaft and slave lever
0.03 to 0.09 0.4 Replace
44, 45 bracket
980 N
14, 36 Installed load of disc spring (Installed length 2) 1.6 kN {160 kgf} Replace
{100 kgf}
30 Bend of connecting link rod 1.25 or less – Replace
37-61
Nut (1st, 2nd and 3rd drag links mounting) 353 ± 88 {36 ± 9} –
Bolt (connecting link pin mounting)
9 to 14 {0.9 to 1.4} –
Bolt (sub cylinder end pin mounting)
Nut (connecting link end mounting) 55 ± 9 {5.6 ± 0.9} –
Nut (slave lever shaft mounting) 34 to 54 {3.5 to 5.5} –
Power cylinder hose 70 to 84 {7.0 to 8.4} –
Nut (power cylinder mounting) 142 ± 47 {14.5 ± 4.8} –
Nut (slave lever bracket mounting)
128 to 176 {13 to 18} –
Nut (power cylinder bracket mounting)

Supply from grease nipple
Multipurpose grease
Tip of connecting link pin As required
End of slave lever shaft
O-ring As required

Slave lever shaft puller

03723-69001 Removal of slave lever shaft
A B C
116 φ50.8 M16 × 1.5
Inspection: Connecting link rod bend
• Measure the bend of connecting link rod at the center point.
• Turn connecting link rod one full rotation and measure the runout
with a dial gauge. The bend is one half of the indicated value.
• If the measured valve is out of the standard value, replace the
connecting link rod.
Inspection: Connecting link rod length

• Adjust the length of connecting link rod by turning connecting
link rod so that the center-to-center distance A between the
holes in connecting link ends conforms to the value shown.
A: 1328.2 mm
37-62
37
Installation: Disc springs
• Install disc spring with the concave side toward washer.
Installation: Connecting link pins and slave lever shafts

• Install connecting link pin and slave lever shaft with grease ap-
plied to their forward ends.
Installation: Lock sheet and side washers

• Install side washers in alignment with bushing between connect-
ing link end and slave lever, one on each side.
• Install connecting link pin, lock sheet and bolts, and bend the
lock sheet at 2 places against the flat of the bolts.
Installation: Sub cylinder end pin

• Install sub cylinder end pin after applying grease to its tip.
Installation: Lock sheet and side washers

• Install side washers in alignment with ball bushing between 1st
drag link and slave lever, one on each side.
• Install sub cylinder end pin, lock seat and bolts in position, and
bend the lock sheet at 2 places against the flat of the bolts.
37-63
Installation: 2nd, 1st and 3rd drag links
• Install 2nd drag link, 1st drag link and 3rd drag link, with the
identification mark “FRONT” existing near the ball joint facing to-
ward the front of the vehicle.
37-64
37
M E M O
37-65
POWER CYLINDER <FS>
1 Dust cover 7 Snap ring 13 O-ring
2 End 8 Dust seal 14 Rod
3 Boot 9 Guide 15 Cylinder
4 Slipper seal 10 Backup ring
5 O-ring 11 U-packing : Non-reusable parts
6 Piston 12 O-ring
Assembly sequence
Repair kit: Seal kit
CAUTION
• When assembling the power cylinder, take care not to let any foreign matter in cylinder.
37-66
37
Looseness
– 0.7 Replace
(under load of 500 N {51 kgf})
2 Ball joint of end
0.5 to 12 N·m
Turning torque – Replace
{0.05 to 1.2 kgf.m}
6, 15 Clearance between piston and cylinder 0.064 to 0.137 0.18 Replace
9, 14 Clearance between guide and rod 0.024 to 0.112 0.12 Replace

Nut (end mounting) 64 to 78 {6.5 to 8.0} –
Nut (piston mounting)
98 {10} –
Guide

Lip area of dust cover Molybdenum disulfide grease As required
Inside of dust cover [NLGI No. 2 (Li soap)] 12 to 14 g
Entire surface of O-ring
Wheel bearing grease
Lip area of dust seal As required
Lip area of U-packing

Dust cover installer

MH061827 Installation of dust cover
A B C
φ65 φ51 100
End holder
A B C D MH061829 Installation of dust cover
φ64 φ55.7 φ35 25
Handle
MC090127 Removing and installing of rod
A
φ49
Guide tool
MC090128 Installation of rod
A
φ50
37-67
POWER CYLINDER <FS>
Press-fit tool MC090130 Press-fitting of dust seal
Protector tool MC090129 Dust seal guide at installation of guide
Punch MC090132 Staking of rod end
Removal procedure
Removal: Rod
• Before removing rod, unstake guide.
Removal: Snap ring

• Insert pin in the snap ring removal hole in guide to remove snap
ring.
37-68
37
Inspection: Ball joint of end
(1) Looseness
• Secure the end in a vise.
CAUTION
• Do not damage the dust cover when securing the end in a
vise.
• If the measured value exceeds the limit when the specified load
(push-in) is applied, replace the end.
(2) Turning torque

• Install a nut on the ball joint of the end.
• Install a socket, adapter and torque wrench, and measure the
turning torque.
• If the measured value is out of the standard value, replace the
end.
(3) Dust cover

• Check that there are no wear, cracks, and damage. These ab-
normalities can cause water to enter the ball joint, resulting in
premature wear.
• If wear, crack or damage is present, inspect traces of water entry
and occurrence of rust in the ball joint. If any abnormality is
found, replace the end. If no abnormality is found, replace the
dust cover and reapply grease.
Installation: U-packing
• Install U-packing, bent heart-shaped, into guide in the direction
as illustrated.
Installation: Dust seal

• Using , install dust seal onto guide in the direction as illus-
trated.
37-69
POWER CYLINDER <FS>
Installation: Guide
• Attach to the threaded end of rod onto which piston is to be
installed, then install guide.
Installation: Piston
• Put a thread cutting die over the piston fitting threaded end of
rod and dress threads.
• Install piston onto rod and tighten nut to the specified torque.
Then, using , stake the rod end at 3 places.
Installation: Rod
• Using , install piston of rod into cylinder.
• Turn the guide-fitted portion of the rod using .
37-70
37
• After installing rod, stake tube end of cylinder at 1 place into the
peripheral groove of guide.
CAUTION
• Avoid staking at the place where a staking has ever been
made.
Installation: End
• Install end to rod and cylinder so that center-to-center minimum
distance between ball studs of the end becomes as illustrated.
Installation: Dust cover

• Fill the inside A and coat the lip of the dust cover with grease.
• Hold the dust cover between and and compress them
with a vise or other appropriate means until the reinforcement
ring closely touches the end.
37-71

Group 37 Steering

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Group 37 Steering

Uploaded by

Copyright:

Available Formats

GROUP 37 STEERING

SPECIFICATIONS ............................................................................. 37-2

STRUCTURE AND OPERATION

TROUBLESHOOTING ...................................................................... 37-8

ON-VEHICLE INSPECTION AND ADJUSTMENT

STEERING COLUMN ...................................................................... 37-18

POWER STEERING BOOSTER AND DRAG LINK ....................... 37-24

POWER STEERING OIL PUMP

POWER STEERING OIL TANK ...................................................... 37-58

CONNECTING LINK ROD <FS> .................................................... 37-60

POWER CYLINDER <FS> .............................................................. 37-66

Power steering oil pump

3.2 When turning the steering

3.3 When hydraulic circuit fails

(1.2) When functioning (oil pump in

(2) Operation of relief valve

Steering angle not enough or different be-

Noise from oil pump (low whirring)

Steering wheel return not smooth

Noise from oil pump (squeaking)

Oil pump oil pressure abnormal

tween right and left

Bearing of sector shaft worn O O

Steering angle not enough or different be-

Noise from oil pump (low whirring)

Steering wheel return not smooth

Noise from oil pump (squeaking)

Oil pump oil pressure abnormal

tween right and left

Front axle deformed O

Steering angle not enough or different be-

Noise from oil pump (low whirring)

Steering wheel return not smooth

Noise from oil pump (squeaking)

Oil pump oil pressure abnormal

tween right and left

Rod bent, piston hitching or worn O

Ball stud loose O O O

Rear axle housing bent O

Lubricant and/or sealant

1.1 Oil leakage

Lubricant and/or sealant

• Start the engine to idle.

• If there is any abnormal noise or a fluid level fluctuation, air

• Perform the tests with the following measuring conditions to ver-

Test item Test procedure Judging standard

Service standards (Unit: mm)

5. Steering Column Looseness

6. Inspection of Rods and Arms for Looseness

Service standards (Unit: mm)

8.1 Drag link and power cylinder ends

• Set a dial indicator on the drag link or power cylinder end as

8.2 Tie rod ends

• After completing zero adjustment, turn the steering wheel to the

Tightening torque (Unit: N·m {kgf·m})

Lubricant and/or sealant

Special tools (Unit: mm)

Steering wheel puller

Removal: Starter switch

Installation: Steering wheel

Work after installation

Lubricant and/or sealant