STEERING SYSTEM

DESCRIPTION

205962

Sequence

1 From hydraulic tank 7 Power steering control valve

2 Hydraulic pump 8 Power cylinder assembly
3 Flow divider valve 9 Bellcrank for rear axle
4 Hydraulic control valve 10 To hydraulic tank
5 Main relief valve 11 Drag link assembly
6 Relief valve for flow divider valve 12 Socket end assembly

This steering is a hydrostatic power steering with The steering control valve features a reaction
a semi-integral (follow-up mechanical) linkage chamber which senses steering load to permit the
which insures steering in the event of power failure. operator to maintain full feel at all times.

The flow divider provides a priority flow to the
steering system for smooth, responsive control
under all operating conditions, even at low engine
speeds.
The steering pressure is regulated by the relief
valve built in the flow divider.
For the flow divider and relief valve, refer to
HYDRAULIC SYSTEM.

9-1
STEERING SYSTEM

REMOVAL AND INSTALLATION

Steering Gear and Power Cylinder
Removal

206784
Sequence

1 Steering wheel [Nut] 7 Steering gear assembly

2 Lever, T/M shift 8 Socket end assembly [Tie rod end assembly,
3 Console box assembly [Clamp and rubber] nut, dust seal and grease fitting]
4 Floor plate 9 Power cylinder assembly
5 Nylon hose and pipe [O-rings and connectors]
6 Drag link assembly [Tie rod end assembly, nut
and drag link]
! WARNING Start by:

Hydraulic pressure can cause personal disconnect the horn wires

injury. Before any steering system hydraulic
lines or components are disconnected, make
sure all hydraulic pressure is released in the
steering system. Move the steer wheels to the
left and right and then to the straight
forward direction.

9-2
 STEERING SYSTEM

Suggestions

1. Removing steering wheel

Use a special tool.

Special tool needed

203466A

2. Removing power cylinder

Raise the rear end by jacking, and block it in raised

condition. Work the truck to disconnect the
power cylinder and take it down by lowering it.

203622

Inspection after removal

Check the drag link for distortion, cracks and

damaged thread. Check the rod end for rattling.
Check the dust seal for damage.

9-3
STEERING SYSTEM

Installation

Assembly dimensions and tightening torques

210292

(1) Assembly dimensions A and B refer to the (2) Be sure to fill up each ball-and-socket joint
exposed threads measured from the end face with grease.
of the nut.

9-4
 STEERING SYSTEM

DISASSEMBLY AND REASSEMBLY

Steering Gear
Disassembly

204903A
Sequence

1 Pitman arm, nut and spring washer 8 Ring plate and needle roller bearing
2 Cap nut, gasket and nut 9 Steering column assembly
3 Side cover, O-ring, shim and adjusting screw [O-ring, needle roller bearing, oil seal and
4 Sector shaft column bushing]
5 End cover and O-ring 10 Ball screw assembly
6 Lock nut, ring plate and needle roller bearing 11 Gear box, snap ring and oil seal
7 Valve assembly 12 Needle roller bearing and O-ring
[Ring plate, valve spool, reaction piston, spring,
pipe seat and valve housing]

Start by:

measure the starting torque of the worm with a

torque wrench or spring scale

9-5
STEERING SYSTEM

Working rules and tips

The steering gear, complete with the control valve,

is a precision-machined component and, as such,
must be handled with greater care. Cleanliness is
of utmost importance: use clean tools and work in
a clean place.

(1) Wash the disassembled parts clean with a

volatile solvent such as trichlene or
chlorobenzene, and dry them with compressed
air: this, however, does not apply to rubber
parts.

(2) Oil seals, O-rings and the like are rubber parts.
Never wash them with the solvent. Blow dirt
off rubber parts with compressed air, and keep
them immersed in a pool of hydraulic oil until
they are used in reassembly. A rubber part
showing even slight tear or wear must be
replaced. Rubber parts am expendable items,
and should be renewed at intervals of one
year.

(3) Parts to be installed by pressing or forcing

need special treatment.

a) Oil seals

An oil seal removed must not be reused in

reassembly. After disassembling, examine the
oil seals in place (in the gear box and side
cover) and, if they are in sound condition,
leave them there. When installing a replace-
ment oil seal, be careful not to score or scratch
its lip portion.

b) Needle roller bearings

These bearings are in the gear box and side

cover, all press-fitted in such a way that they
are not replaceable. If any of the needle roller
bearings is found in worn-down or otherwise
defective condition, replace the whole gear
box and side cover assembly.

9-6
 STEERING SYSTEM

Suggestions

1. Removing pitman arm

Mark the pitman arm and sector shaft before
disassembly.

Use a pitman arm puller or gear puller.

Special tool needed

200294

2. Removing side cover

The cover comes off as the adjusting screw is

turned clockwise.

3. Removing sector shaft

Rotate the worm to bring the sector shaft to the

position shown, and lightly drive on the serrated
end of the shaft to force it out of the box.
200295A

4. Loosening staked lock nut

Use a screwdriver.

200296A

5. Disassembling control valve

Remove the control valve from the gear box, and

pull the spool straight out, taking a firm grip on its
head. Set the valve body on the work table as
shown, and take out the internals by lifting them
straight up.

200297

9-7
STEERING SYSTEM

6. Removing needle roller bearing

Use a special tool to remove the bearing from the

steering column assembly as shown.

Special tool needed

206465

7. Removing ball-screw assembly

Clamp the gear box in a vise, as shown, and pull

out the assembly in level direction. If any part of
this assembly is in bad condition to require
replacement, replace the whole assembly.

200299A

Inspection after disassembly

1. Control valve

Inspect the valve sleeve and spool for wear, rusting

and surface flaws such as scuffing, grooving,
scratching, etc., and, as necessary, replace the two
together.

200306

2. Sector shaft

(1) Increase or decrease the shim thickness to

obtain a clearance of less than 0.1 mm [0.004
in.] between adjusting screw and sector shaft.
If the head of the adjusting screw is worn
down, replace the screw.

(2) Replace the sector shaft if it is badly worn,

damaged or cracked. 200301

9-8
 STEERING SYSTEM

3. Ball-screw assembly

(1) If the recirculating-ball nut rotates sluggishly

on the screw, wash the assembly in washing
fluid, and test it again for smoothness of
rotation.

(2) Check the steering shaft for distortion with a

dial indicator, as shown; if the indicator
reading taken exceeds the limit, replace the
shaft complete with the ball nut. 200302

A = Assembly standard
B = Repair or service limit Unit: mm[in]

9-9
STEERING SYSTEM

Reassembly

203587

206466

Sequence

1 Gear box, bushing, needle roller bearing, oil 5 End cover and O-ring
seal and snap ring 6 Gear shaft, side cover, needle roller bearing,
2 Ball screw assembly O-ring, shims, adjusting screw, nut and cap nut
3 Steering column assembly [Column bushing, 7 Pitman arm, spring waster and nut
oil seal, ball bearing and O-ring]
4 Valve assembly [Valve housing, pipe seat,
spring, reaction piston, valve spool, ring plate,
needle roller bearing and lock nut]

9-10
 STEERING SYSTEM

Suggestions

1. Reassembling gear box

Be sure to position the oil seal (for sector shaft) as

shown, pushing it into the bore until it barely clears
the snap ring groove; and secure the seal by snugly
fitting the snap ring.

200304

2. Installing ball-screw assembly

Make sure that the largest-diameter part of the

worm shaft snugly fits into the needle roller bear-
ing in place.

200305A

3. Reassembling column assembly

Both needle roller bearing and oil seal are meant

to be pressed into the rear cover.

NOTE
When pressing in the oil seal, be careful to
prevent oil leaks.

206467

4. Reassembling control valve

(1) Align “P” mark of the sleeve with the smaller

inside chamfer of the spool. Be sure to insert
and position the reaction piston and center
spring correctly.

200300

9-11
STEERING SYSTEM

(2) Install the needle roller bearing and plate.

Then, install the valve with “P” mark of the
sleeve on the front cover side.

200307

(3) After installing the plate and needle roller

bearing, attach set plate A (special tool)
on the control valve. Tighten the lock nut
to 39 to 49 N• m (4 to 5 kgf•m) [29 to 36
lbf•ft] and stake it at two places. Then,
make sure that the starting torque of the
shaft is less than 0.8 N m (8.2 kgf•cm)
[0.6 lbf•ft]. After staking the lock nut,
make sure that the valve does not rattle.
200308
Special tool needed

5 Installing end cover

6 Installing sector shaft

Center the ball nut as seen in the opening, and

insert the sector shaft, positioning the two as in
straightahead driving. Secure the side cover by
tightening its securing bolts to the specified torque.

200309

9-12
 STEERING SYSTEM

7. Installing pitman arm

The angular position of the pitman arm is fixed and

identified by a match mark given to the sector shaft.
Feed the arm onto the serrated portion of the shaft
and secure the arm by tightening its nut to the
specified torque.

200310A

Inspection after reassembly

1. Backlash

Center the ball nut and, while holding the nut

steady, try to turn the pitman arm back and forth.
Use a dial indicator to measure the movement of
the free end of pitman arm, at a point exactly 195
mm [7.677 in.) from the axis of sector shaft. The
backlash, expressed in terms of this movement,
must be reduced to within the limit by reposition-
ing the adjusting screw. The torque value for
tightening the lock nut on this screw is specified. 200311A

2. Pitman arm swing angle

Rotate the steering wheel lock-to-lock and measure

the swing angle of the pitman arm.

200312

9-13
STEERING SYSTEM

3. Steering wheel starting torque (steering wheel

side)

Hold the steering gear assembly in a vise with the

pitman arm in vertical position and check the
starting torque in both directions.

204904A

4. Steering shaft rotation

Hold the steering gear assembly in a vise with the

pitman arm in vertical position and make sure that
the steering shaft rotates smoothly in both
directions.

9-14
 STEERING SYSTEM

Power Cylinder
Disassembly

205030

Sequence

1 Guide assembly [Dust seal, packing, bushing 3 Piston rod

guide and O-ring] 4 Cylinder tube, tie rod end, nut and pin
2 Piston, self-locking nut and seal

Suggestions
Removing guide

(1) Loosen the staked spot of the cylinder tube,

using a pointed tool or, say, a screwdriver,
with the cylinder gripped in a vise at its port
(elbow) section.

200316

9-15
STEERING SYSTEM

(2) Put a special tool, hitching it to the notches

provided in the guide, and turn the guide
counterclockwise to loosen it until its threaded
portion comes off.

Special tool needed

(3) Remove the piston rod complete with the 200317

guide and piston from the cylinder tube.

(4) To remove the guide from the piston rod,

remove the piston and pull out the pin.

Inspection after disassembly

1. Cylinder tube

Check the cylinder tube for wear, scuffing, scratch

marks and rusting at its bore surface.

2. Piston rod

Check the piston rod for dents, scoring and wear,

and check for deflection.

200319

3. Sealing parts

Replace the dust seals, packings and O-rings at the

time of disassembly or every 1 year.

9-16
 STEERING SYSTEM

Reassembly

To reassemble, follow the reverse of disassembly

sequence and do the following steps:

1. Installing dust seal

Using a spatula-like tool, fit the dust seal to the

guide.

2. Installing guide bushing

Using a special too, install the guide bushing to the

piston rod.

Special tool needed

Rod cap 91268-13600

3. Installing piston
205031
Put the piston on the piston rod, and tighten the
self-locking nut to the specified torque.

4. Installing piston rod

Using a special tool, gently insert the piston rod

into the cylinder tube.

Special tool needed

Guide 91268-12900 200320

NOTE
Apply hydraulic oil sufficiently to the piston
and the inside surface of cylinder tube

5. Tightening guide bushing

Tighten the guide bushing to the specified torque.

9-17
STEERING SYSTEM

6. Staking cylinder tube

Connect the steering hose to the power cylinder

assembly. Apply hydraulic pressure to the cylinder
to make sure that the cylinder is free from leakage.
Then, stake the tube at one place.

INSPECTION AND ADJUSTMENT

Steering Wheel Free Play

With the engine running at low idle, measure the

free play at the wheel rim.

NOTE
The control valve spool movement will be
evidenced by a steering wheel movement of 170
to 175 mm [6.7 to 6.9 in.]. Do not confuse this 204905A
movement with the free play.

If the free play is off this range, correct it by

referring TROUBLESHOOTING.

Steering Effort

1. Set the parking brake. Run the engine to warm

up the hydraulic oil (until the engine coolant
temperature gauge needle moves into the white
zone).

2. Hook a spring scale to the rim of steering wheel

and turn the wheel. Read the scale when the
wheel begins to turn with the engine idling. 204904A
This effort should not exceed the standard value.

Stering effort 20N (2 kgf [14 lbf]

Relief Valve Setting Adjustment

Refer to HYDRAULIC SYSTEM.

9-18