STEERING SYSTEM

GENERAL POWER STEERING SYSTEM

DESCRIPTION .............................................. ST - 2 POWER STEERING GEAR BOX
SPECIFICATIONS ......................................... ST - 7 COMPONENTS ....................................... ST - 27
TROUBLESHOOTING .................................. ST - 10 DISASSEMBLY ........................................ ST - 28
REASSEMBLY ........................................ ST - 31
STEERING COLUMN AND SHAFT POWER STEERING OIL PUMP
COMPONENTS ............................................ ST - 15 COMPONENTS ....................................... ST - 37
COMPONENT LOCATION ............................ ST - 17 DISASSEMBLY ........................................ ST - 39
REMOVAL ..................................................... ST - 18 INSPECTION ........................................... ST - 42
INSTALLATION ............................................. ST - 19 REASSEMBLY ........................................ ST - 43
ADJUSTMENT ........................................ ST - 47
STEERING LINKAGE
DRAG LINK
REMOVAL ............................................... ST - 20
INSTALLATION ........................................ ST - 20
TIE ROD
REMOVAL ............................................... ST - 21
DISASSEMBLY ........................................ ST - 22
REASSEMBLY ........................................ ST - 24
SLAVE LEVER
DISASSEMBLY ........................................ ST - 25
REASSEMBLY ........................................ ST - 26
ST -2 STEERING SYSTEM

GENERAL STEERING LINKAGE

DRAG LINK ASSEMBLY

DESCRIPTION E96B1119
Rigid suspension type : The drag link transmits the force of
The steering system allows the driver to freely change the power steering gear pitman arm to slave lever and knuckle
traveling direction of the vehicle. The force applied to the arm.
steering wheel is transmitted through the steering shaft,
sheering gears, pitman arm and drag link to the knuckle
arm to achieve steer the vehicle.
The system has an integral type power steering gear in- Ball joint
stalled in the gear box to reduce the steering effort.
The power steering system hydraulic pressure circuits are
as shown below.

Oil reservoir Oil pump Power steering gear

Piping

SPYST7001L

STEERING WHEEL AND SHAFT

SPYST7003L

The steering shaft is a telescopic and tilt type which can
by adjusting lock lever select the best driving position by
adjusting lock lever.
Tilt
TIE ROD ASSEMBLY
Rigid suspension type : It connects the left and right tie-rod
arm
The connecting point of tie rod and tie rod end is tightened
by a left hand bolt at left and a right hand bolt at right.

Lock lever

Ball joint
Tie rod

Telescopic

SPYST7002L
Tie rod end

SPYST7004L
GENERAL ST -3

SLAVE LEVER (RIGID SUSPENSION)

The slave lever connects the 1st drag link and 2nd drag by
multiplying the force from 1st drag link to 2nd drag link.

Slave lever

1st drag link

2nd drag link

SPYST7005L

INTEGRAL POWER STEERING GEAR

This device consisting of the power cylinder section (out-

put section) that also serves as the steering gear and the
control valve section (control section) reduces the power
required to operate the steering wheel.
ST -4 STEERING SYSTEM

STRAIGHT AHEAD DRIVING

When there is no steering torque from the steering wheel,

no relative displacement is caused between the stub shaft
and the worm shaft and hence the rotor (or spool) is at the
neutral position on the worm shaft (or sleeve). Accordingly,
the hydraulic oil supplied by the oil pump is allowed to flow
through the worm shaft groove back to the oil tank.
Namely, no pressure difference develops between cylinder
chambers A and B so that the piston (ball nut) remains
stationary at the neutral position.

To cylinder
1 chamber B
To oil tank From oil pump
3
2 To cylinder To cylinder
chamber A chamber A

4 From oil pump To oil tank

To cylinder To cylinder
chamber B chamber B
6 To oil tank From oil pump
5 To cylinder
chamber A
7 6
1. Rotor
2. Stub shaft
3. Cylinder chamber A
4. Piston
5. Torsion bar
6. Worm shaft
7. Cylinder chamber B

SPYST7006L
GENERAL ST -5

RIGHT TURN

When the steering wheel is turned clockwise, the load from

the tires acts on the worm shaft to twist the torsion bar.
As a result, the rotor turns clockwise with respect to the
worm shaft, decreasing the axial direction groove clear-
ance. This limits flow of the hydraulic oil to the oil tank and
now the hydraulic oil from the oil pump enters the cylin-
der chamber A to cause the piston to move to the cylinder
chamber B.
The hydraulic oil in the cylinder chamber moves, the tor-
sion bar that has been twisted returns to the neutral po-
sition. The force that has caused twisted returns to the
neutral position. The force that has caused twisting of the
torsion bar during steering is transmitted to the steering
wheel as a steering reaction force which gives the driver a
sense of steering response.
A left turn is also made on the same operating principles
as the right turn but in opposite direction.

To cylinder
chamber B

1 To oil tank From oil pump

3 To cylinder To cylinder
2 chamber A chamber A

From oil pump To oil tank

4 1
To cylinder From cylinder
chamber B chamber B

6 To oil tank From oil pump

To cylinder
5
chamber A

7 6
1. Rotor
2. Stub shaft
3. Cylinder chamber A
4. Piston
5. Torsion bar
6. Worm shaft
7. Cylinder chamber B

SPYST7007L
ST -6 STEERING SYSTEM

MANUAL STEERING

Even if the hydraulic pressure ceases to act on the power

steering booster due to a stalled engine, defective oil
pump, oil leaks or other causes, the mechanical power is
directly transmitted from the stub shaft to the worm shaft
by the stopper mechanism provided between the stub
shaft and worm, allowing manual steering.

Warm shaft Torsion bar

Stub shaft

SPYST7008L
GENERAL ST -7

SPECIFICATION EF5E0D6A

Item LS, LD, LDX

Steering wheel Type (O.D) 4-spoke type (Ø470)
Steering shaft Type Universal joint (with telescopic tilt mechanism)
Power steering gear Type Ball-nut type
Gear ratio 17.0
Area of servo piston (cm²) 95.0
Maximum inlet pressure (kgf.cm²) 140
Spring constant of torsion bar
200
(kgf.mm/deg)
Oil capacity lit Approx.1.5
Power steering oil pump Type Vane pump type
Displacement (no load) cc/rev. 25
Controlled flow lit./min. 16
Permissible rotating range, rpm 500~3500
Relief valve adjusting pressure kg/cm² 130
ST -8 STEERING SYSTEM

SERVICE STANDARDS

Nominal Value
Service limit Remedy and Remarks
(Basic diameter)
Integral Play of ball nut assembly in axial 0.04 Replace as assembly
power direction
steering
Body (cylinder) to ball nut (piston) [100] 0.11 0.16 Replace
gear
clearance
Rotor (O.D.) to worm shaft clearance Clearance Replace as assembly
[35.5] 0.01~0.03
exceeding 0.03
Sector shaft Pitman arm side 57.97 57.87 Replace
O.D.
Adjusting screw side 47.97 47.87
Backlash between ball nut (piston) 0.2~0.5 Adjust
rack and sector shaft gear Measure at pitman arm
end (=300) with the
steering in neutral position
Starting torque of sector gear 295 or less (30 Adjust by adjusting plug
N com (kgf.m) or less)
Steering Play of steering wheel 24 or less Adjust
wheel
Play in axial direction of steering 0.2 or less Correct or replace as
and shaft
shaft and column assembly
Play in Joint section (play of 15 or less Replace as assembly
turning needle roller bearing
direction and spider)
Play of yoke spline 30 or less 0.2
tube and lower shaft
(spline shaft)
Steering Clearance between slave lever 0.015-0.111 [38] Replace
linkage shaft and bushing
Clearance between connecting 0.045-0.175 [42] Replace
link pin and bushing
Power Ridge wear on pressure plate and 0.09 No sticking, wear and
steering side plate surfaces in friction with streaks
oil pump rotor and vane
Flow control valve to rear body clearance 0.03 Replace
No sticking, wear and
streaks
Replace as flow control
valve assembly or rear
body assembly
GENERAL ST -9

TIGHTENING TORQUE

Part to be tightened Nm kgf.m

Steering shaft Steering wheel nut 78 8
Steering shaft bearing tightening nut (lock plate) 39~69 4~7
Steering shaft yoke bolt 48~63 4.9~6.4
Lock plate stopper bolt 3.9~6.4 0.4~0.65
Worm shaft and yoke attaching bolt 49~54 5.0~5.5
Linkage Ball stud castle nut 200~340 20.7~34.5
integral power
Pitman arm nut 390~440 40~45
steering gear
Ball tube screw 4.4~5.4 0.45~0.55
Taper plug 8.8~1.3 0.9~1.3
Retainer Tighten fully, turn back by 180 , tighten
again to 39(4), then turn back by 20 and
stake.115~125 (11.5~12.5)
Adjusting screw lock nut 120~130 12~13
Side cover bolt 50~65 5.5~6.5
Adjusting plug 230~250 23~25
Valve housing bolt 120~130 12~13
Plug (air breather) Tighten to 115 (12) and stake at 2
point 295~390 (29~39)
P/S oil pump Plug 300~400 30~40
Cartridge assembly screw 49~59 0.6~0.9
Rear body bolt 49~59 5~6
Flow control valve plug 49~59 5~6
Hose connector bolt 18~25 1.8~2.5
Oil pump gear tightening nut 90 9
ST -10 STEERING SYSTEM

TROUBLESHOOTING E1A40A1D

Symptom Probable cause Remedy

Hard steering Power Thrust bearing damage Replace the thrust bearing
steering gear
Ball of ball screw worn Replace screw and housing
mechanism
assembly
defective
Low fluid level in oil tank Add fluid
Air in oil circuit not completely bleed Bleed air
Improper fluid viscosity Replace fluid
Trouble in power steering gear system Replace
Incorrect pipe connections Correct
Defective oil pump (or malfunction) Replace
Flow control valve in faulty operation Replace
Steering Universal joint abnormally worn, damaged Replace steering shaft
linkage or poorly lubricated assembly or apply grease
defective
Deformed linkage Replace drag link
Front axle King pin poorly lubricated Apply grease
defective
Correct front wheel
Poor front wheel alignments(toe-in, camber, caster)
alignments
Front wheel tires under inflated Inflate as specified value
Thrust bearing damaged Replace
Other troubles Passengers are unevenly loaded in the front. Disperse the load evenly
Unstable Power Worn rack and gear in ball screw unit Replace the gear
steering steering gear
Worn bearing in sector shaft Replace the gear
because of mechanism
excessive free defective Worn ball in ball screw Replace the gear
play of steering Loose power steering gear mounting bolts Tighten to the specified
wheel torque
Air trapped and air not completely bleed Add fluid and bleed air.
Steering Looseness in universal joint Pack with grease.
linkage If the problem still
defective persists,replace steering
shaft assembly
Looseness in drag link ball stud Replace the drag link
Looseness in tie rod end ball stud Replace tie rod end
Front axle Worn wheel hub bearing Replace
defective
Worn king pin or bushing Replace
Other troubles Uneven brake application Readjust or replace lining
GENERAL ST -11

Symptom Probable cause Remedy

Vehicle pulls to Front axle Improper wheel alignment Correct
one side steering system
Deformed front axle Replace
defective
Worn or deformed wheel hub bearing Replace
Worn or deformed king pin Replace king pin or bushing
Steering wheel is off-center Correct
Power steering gear defective Replace
Other troubles Broken leaf spring Replace
Uneven brake application Repair
Right and left tires unevenly inflated Inflate properly
Right and left tires greatly different in the Replace tires
degree of wear
Right and left tires different in axial distance Correct axial distance
Bent rear axle housing Replace axle housing
Steering wheel Front axle Excessive clearance between king pin and bushing Replace king pin or bushing
jerks assembly
Worn or deteriorated wheel hub bearing Replace
defective
Improper wheel alignment(particularly Correct wheel alignment
camber and caster)
Looseness in knuckle arm or tie rod ball stud Replace knuckle arm
or tie rod
Excessively uneven tire pressure Adjust tire pressure
Knuckle arm, tie rod arm, backing plate and Tighten to the specified
knuckle, etc. Improperly tightened torque
U-bolt, nut, etc. of front spring loose Tighten to the specified
torque
Lateral and radial run outs of front tires, and Correct wheel balance
incorrect static and dynamic balance
Power steering Improper play in ball screw unit and sector shaft Adjust
gear steering
Worn thrust bearing Replace
system
defective Defective power steering gear Correct or replace
Looseness in ball stud of drag link Replace knuckle arm,
pitman arm or drag link
Worn sector shaft and bearing Replace the gear
Worn ball and groove in ball screw Replace the gear
Other troubles Excessive runout of propeller shaft Correct or replace
Reduction pinion and gear damaged and Replace pinion and gear or
in poor tooth contact correct tooth contact
Excessive tire runout Repair or replace
ST -12 STEERING SYSTEM

Symptom Probable cause Remedy

Hard steering in Power steering Low pressure due to fluid leaks Retighten leaky parts
both clockwise gear system or replace seal ring,
and counter defective O-ring. etc.
clockwise
Valve malfunctioning Check and correct valve
directions
or replace screw and
housing assembly
Piston damaged or foreign substance clogged Check for foreign substance
in hydraulic fluid, and clean
and check inside surface
of body and sliding surface
of piston, or replace screw
and housing assembly.
Hard steering Rack mesh torque out of adjustment Adjust stub shaft rotating
particularly in torque
neutral
Great Clogged hydraulic circuit Check and correct hydraulic
difference circuit or replace screw and
in steering housing assembly
effort between
clockwise
and counter
clockwise
rotations
Hard steering Air trapped due to low fluid level Bleed air and then add fluid
particularly
during idling
Hard steering Valve malfunctioning Check and correct valve
particularly at or replace screw and
beginning housing assembly
Hard steering Defective oil pump Replace oil pump
due to
Clogged hydraulic piping Correct or replace piping
problems not in
power steering Insufficient grease in steering linkage joints Pack joints with grease
gear Insufficient front tire inflation pressure Adjust to the specified
air pressure
Incorrect front wheel alignments Measure wheel alignments.
If incorrect, adjust to the
specified value
King pin bearing damage Replace
King pin short of grease Apply grease to king pin
Hard steering Power steering Valve and roll edge damaged or control seal Replace screw and housing
particularly gear defective ring or O-ring damaged assembly
during idling
Improper fluid in power steering system Replace with the specified
hydraulic fluid
GENERAL ST -13

Symptom Probable cause Remedy

Steering wheel Problems not in Uneven tire pressure Adjust to specified pressure
vibrations power steering
Incorrect front wheel alignment Measure wheel alignment.
gear
If incorrect, adjust to
specified value
Front wheels out of balance Rebalance with wheel
balancer or replace
tires or wheels
Worn drag link or tie rod end ball joint Replace drag link assembly
ortie rod end
Worn king pin and king pin bushing Disassembly and replace
if defective
Poor return Power steering Rack torque out of adjustment Adjust stub shaft torque
ability of Wheel
Clogged hydraulic circuit Check and correct circuit
steering wheel defective
or replace screw and
housing assembly
Clogged hydraulic piping Correct or replace piping
Front wheel alignment off Measure wheel alignment.
If in-correct, adjust to
specified value
Vehicle Worn sector shaft gear Adjust steering wheel play
wanders due with adjusting screw of
to excessive replace sector shaft
play of steering
Damaged or worn stub shaft serrations Replace screw and housing
wheel
assembly
Grinding noise Air in oil pump Check fluid level and
hose clip, bleed air, or
replace oil pump
Seizure of parts in oil pump
Grinding noise Seizure of parts in oil pump Replace oil pump
Squeaking Loose pump bracket mounting bolts and nuts Retighten to specified
noise torque
Defective pump Replace oil pump
Abnormal Maximum generated hydraulic pressure insufficient Disassemble, check,
hydraulic due to defective oil pump and correct, or replace
pressure in defective parts
oil pump
Hydraulic pressure generated during idling is excessively Correct or replace hose
high due to clogged hydraulic line or pipe
Strange sound,
The oil pump produces some howling sound which is not an
vibration or
indication of any functional problem(particularly when turning
noise from oil
the steering wheel while the vehicle in standstill)
pump
Strange sound, Worn bearings Replace
vibration or
Mounted or jointed parts loose Retighten to specified
noisefrom oil
torque and replace
pump
detective parts
ST -14 STEERING SYSTEM

Symptom Probable cause Remedy

Steering angle Incorrect pitman arm mounting angle Mount at correct position
is insufficient or
Knuckle stopper bolt out of adjustment Using turning radius
clock-wise and
counterclock- gauge, adjust clockwise
wise steering and counterclockwise
angles are dif- steering angles with
ferent knuckle stopper bolts

Fluid leaks Fluid leaks from steering gear Retighten leaky parts to
specified torque or replace
O-ring, seals, etc.
Fluid leaks from power steering gear Retighten leaky parts to
specified torque or replace
O-ring, seals, etc.
Fluid leaks from Defective oil pump housing Disassemble, check and
oil pump replace if defective
Defective gasket, oil seal Disassemble, check and
replace if defective
Loose bolts Retighten to the specified
torque
Fluid leaks from Fluid leaks from oil tank due to overfilling Adjust to the specified level
oil tank
Fluid leaks from oil tank due to trapped air Bleed air and adjust to
specified level
Improperly welded pipes Braze or replace
Loose hydraulic piping and connections Retighten to the specified
torque or replace
STEERING COLUMN AND SHAFT ST -15

STEERING COLUMN AND

SHAFT
COMPONENTS EFAB79F9

[ LD ]

8~9
2

8.5~11 23.9~32.3
22~32
4
47~63
7

5~6

23.9~32.3 8
6

22~32

1. Steering wheel
2. Column shaft
3. Dust cover
4. Support
5. Power steering gear
6. 1st Drag link
7. Idler arm
8. 2nd Drag link

Tightening Torque : kgf.m

SPYST7009L
ST -16 STEERING SYSTEM

[ LS, LDX, HSX ]

21.1~34.1

5.5 47~63

40~45
2
11

3 22~32
55~70
10
5~5.5
8
4

8.5~11
5~5.5
9
7
22~32
6

5
8.5~11
1. Steering wheel
2. Column shaft
3. Dust cover
4. Support
5. Bevel gear
6. Universal shaft
7. Power steering gear
8. Pitman arm
9. Drag link
10. Knuckle arm
11. Tie rod

Tightening Torque : kgf.m

SPYST7010L
STEERING COLUMN AND SHAFT ST -17

COMPONENT LOCATION EFE71323

13 23 22
18
12

14
3 4
5 8

33

20
15
16
17 10 27
11 29
7 28
30 31 21 25 24 26
19
6

32
34

1. Steering shaft 13. Snap ring 25. Plain washer

2. Column outer 14. O-ring 26. Self lock nut
3. Mounting bracket 15. Bolt 27. Upper bushing
4. Upper plate 1 16. Nut 28. Bolt
5. Upper plate 2 17. Washer 29. Ball bearing
6. Lower plate 1 18. Bushing 30. Bolt
7. Lower plate 2 19. Cam 31. Washer
8. Bolt 20. O-ring 32. Packing
9. Nut 21. Tilt lever 33. Bolt
10. Lock plate 22. Adjust bolt 34. Universal joint assembly
11. Needle bearing 23. Adjust bushing
12. Ball bearing 24. Thrust bushing

SPYST7014L
ST -18 STEERING SYSTEM

REMOVAL EE8130C1 7. Support the column end with vice.

1. Disconnect the battery (-) terminal.

2. Detach the column cover.

3. Remove the all starter switch connector and cable

band.

4. Remove the multi function switch connector.

5. Insert key and turn to "ON" position.

Remove the engine stop cable from starter switch.

SPYST7012L
Multi function
switch
8. Remove the starter switch by inserting a twist off bolt.
Connecter
1) Drill a hole of 5.5~6.0mm diameter and
10~15mm depth on bolt head for twist off.
Cover
Start switch 2) Insert a screw extractor and turn counter clock-
wise direction to extract the bolt.

3) Remove the starter switch from steering column.

SPYST7011L

6. Remove the starter switch with upper and lower shaft Screw extractor
assembly as following Bolt head detached
surface
1) Before removing, fix the steering wheel not to
turn and mark an mating mark on spline shaft and
spline tube.

2) Remove the dust cover from the end of column

shaft and remove the support attaching bolt.

3) Remove the lock lever and clutch set attaching

bolt.

4) Pull the upper and lower shaft assembly up and

remove. SPYST7013L
STEERING COLUMN AND SHAFT ST -19

STEERING WHEEL INSTALLATION E265F8B4

1. Remove the horn pad(A) and wiring connector(B). 1. Tighten a new twist off bolt to 13~15 Nm (1.3 ~ 1.5
kgf.m) and extract the twist off bolt head.
2. Remove the wheel using a steering wheel puller.
Mark an mating mark for reassembly. 2. Inspect the function of steering lock operation after
installation.
A
3. Installation is the reverse procedure of removal.
B

Starter switch

SPYST7016L Twister off bolt

STEERING SHAFT
SPYST7015L
1. Detach the dust cover from column end and remove
the steering cover attaching bolt.

2. Make an align mark on steering shaft joint, power

steering gear, and stub shaft. Then tightly tighten the
steering lock lever.

3. Remove the link and steering shaft attaching bolt of

bracket.

4. Remove the steering shaft joint attaching bolt.

5. Remove the steering shaft assembly from stub shaft

with installed starter switch.

Link and Bracket

Spline shaft assembly

SPYST7017L
ST -20 STEERING SYSTEM

STEERING LINKAGE INSTALLATION ECE841FB

LD — DRAG LINK
DRAG LINK
1. Installation of dust cover
Fit the dust cover over the end and pinch them be-
REMOVAL E92EB3ED tween the special tools, dust cover installer and end
holder. Using a vise, press-fit the dust cover until the
1. Straighten the end of split pin of the drag link, pinch reinforcement ring is held tight-up against the end.
the split pin head with pliers and remove the split pin, Check the dust cover if evenly fitted.
remove the nut, then remove the drag link.
2. Fit the dust cover in drag link flute and fill dust cover
NOTE with grease.
Do not reuse the split pin once removed.

2. Disassembly Dust cover installer

NOTE Reinforcement Coat lips with grease

ring
LS, LDX, HSX : Dust cover Apply grease
Do not disassemble the drag link as it is no maintain- (molybdenum disulfide
base grease)
able.

[LD - 1st drag link] Reinforcement ring

Idler side
End
22~32Kgf.m

End holder
22~32Kgf.m

SPYST7020L
Steering gear side

3. Torque the nut to specification and fit a new split pin

[LD - 2nd drag link] into position.
22~32Kgf.m
Idler side 4. After installation, check and adjust toe-in.

Knuckle arm side

22~32Kgf.m
SPYST7018L

[LS, LDX, HSX]

Steering side

22~32Kgf.m
22~32Kgf.m

Knuckle arm side

SPYST7019L
STEERING LINKAGE ST -21

TIE ROD

REMOVAL EBBB8588

[ LD ]

Split pin

Tie rod arm

Tie rod

Nut

SPYST7021L

NOTE
Do not reuse the split pin once removed.
ST -22 STEERING SYSTEM

DISASSEMBLY E33B176F

[ LD ]

1. Aging, crack

3. Damage

1. Dust cover
2. Tie rod end
2. Damage 3. Tie rod

SPYST7022L

[ LS, LDX, HSX ]

2 3

1. Split pin
2. Ball joint
3. Clamp
4. Tie rod

NOTE
Tie rod end assembly is not removable part. Never attempt to disassemble.
Do not disassemble the dust cover unless damaged.

SPYST7077L
STEERING LINKAGE ST -23

1. Inspection of ball stud 2. Inspection of tie rod

Move the ball stud section up and down and right and
left to check for any excessive play. Check to see if
the ball section rocks around evenly.
[ LD ]
Put a V-block on a precision table and fix the dis-
tance from both(right and left) ends to the center of
the V-block, as the illustration.
Then turn the tie rod, to check vibration of the outer
circumference.
If the measurement is out of the specified value, re-
place it.

Ball stud
section

Ball section
Approx.250mm Approx.250mm
Tie rod

Tie rod end

SPYST7023L Block Tie rod

[ LS, LDX, HSX ]

SPYST7024L

SPYST7076L
ST -24 STEERING SYSTEM

REASSEMBLY E90BFBE9

[ LD ]
Length between ball stud 1773.3

22.1~33.1kgf.m
Pack grease
Apply grease

8kgf.m

<Reassembly sequence>
Refer to the following reassembly procedures with an encircled number.

SPYST7025L

Installation of dust cover

Fit the dust cover over the end.
Using a dust cover installer, end holder and a vice, press-fit
the dust cover until the reinforcement ring is in contact with
the end. Make sure that the dust cover is held straight.

NOTE
Do not re-use the used dust cover.

Dust cover installer

Reinforcement Coat lips with grease

ring
Dust cover Apply grease
(molybdenum disulfide
base grease)

Reinforcement ring
End

End holder

SPYST7026L
STEERING LINKAGE ST -25

SLAVE LEVER

DISASSEMBLY EAF15C0D

[ LD only ]

Hub cap
Shaft to bearing clearance
Bearing (outer) NV .... 0.003-0.025 mm
Slave lever
Bearing (inner)
Oil seal
Slave lever shaft

Slave lever bracket

Slaver lever to bearing clearance

NV .... 0.004-0.039 mm

NV .... Nominal valve

SPYST7027L
ST -26 STEERING SYSTEM

REASSEMBLY EE12E8EB

[ LD only ]

163mm

12 5 Apply grease
8 7 4
9
6 Press 1. Idler arm
10 11 2. Idler arm bracket
0.7~1.1 3. Cab
4. Inner bearing
5. Hub oil seal
2
6. Idler shaft
7. Washer
8. Hub bearing lock nut 1
9. Hub bearing lock nut 2
3 10. Bolt
20~24 11. Washer spring
12. O-ring
1
Tightening Torque : kgf.m
Pack grease

SPYST7028L
POWER STEERING SYSTEM ST -27

POWER STEERING SYSTEM

POWER STEERING GEAR BOX

COMPONENTS EC61E485

11
14
12 Axial play of ball nut
16 assembly
15
33 L 0.04 mm
Body (cylinder) to ball
17
nut (piston) clearance
19
BD 100 mm
18
Sector gear 24 NV 0.11 mm
22 L 0.16 mm
backlash
21 13
NV 0.1~0.35mm
23 Sector shaft O.D.
Rotor (O.D.) to worm
shaft clearance Pitman arm sie Adjusting screw side
BD 35.5 mm 25 NV 57.97 mm NV 47.97 mm
NV 0.01 ~ 0.03 mm L 57.93 mm L 47.93 mm
L 0.03 mm 20 26
31

5
32 30 Rotation
Aging,
damage 27 29 28
2 3
34

1
4
33
6
7
BD ... Basic Diameter 9
NV ... Nominal Value 8
10 Rotation
L ... Limit

1. Taper plug 9. Backup ring 17. Side race 25. Seal ring
2. Pitman arm 10. Needle roller bearing 18. Steel ball 26. Plug
3. Lock nut 11. Dust cover 19. Bearing cage 27. Oil seal
4. Side cover 12. Valve housing 20. Worm shaft 28. Y-packing
5. Sector shaft 13. Piston (Ball nut) 21. Rotor 29. Backup ring
6. Retainer 14. Adjusting plug 22. Seat ring 30. Needle roller bearing
7. Adjusting screw 15. Ball bearing 23. Stub shaft assembly 31. Body
8. Y-packing 16. Y-packing 24. Seal ring 32. Plug (air breather)
33. O-ring
NOTE : 34. Bleed valve
1. Do not remove the needle bearing ring of the side cover unless defects are evident.
2. Do not disassemble the sector shaft unless defects are evident.
3. Do not remove needle bearing and taper plug from the body unless defects are evident.
4. Ready a receiver to receive steel balls whenever part containing them is to be disassembled.
5. Align the stamped marking on sector shaft end face with the center marking of body to note the neutral
position of the sector shaft.
6. Stroke the piston from the end to remove any residual oil.

SPYST7029L
ST -28 STEERING SYSTEM

DISASSEMBLY E90EDFC1 3. Turn the adjusting screw clockwise with a screwdriver

to remove the side cover assembly from the sector
1. Removal of pitman arm from the power steering gear. shaft assembly.

SPYST7030L SPYST7032L

2. Removal of side cover 4. If defects are evident on the sector shaft assembly,
use the following procedure to disassemble it.
1) Remove the nut that secures adjusting screw and
side cover mounting bolt. 1) Straighten retainer at two places where it is
staked.
2) Make sure that the piston is in the neutral posi-
tion. Then, tap the end face of the sector shaft NOTE
with a plastic hammer (or mallet) to remove the
sector shaft assembly, together with the side When clamping the sector shaft in a vise, cover it with
cover. a cloth to prevent it from being damaged.

NOTE Adjusting screw

Never use a steel hammer.

Retainer

Sector shaft

SPYST7033L

SPYST7031L
POWER STEERING SYSTEM ST -29

2) Remove the retainer then remove the adjusting 6. Remove the bolt(A) and remove the screw and hous-
screw. ing assembly(B).

NOTE
• Take care not to allow the ball to jump out of the
ball screw.
• Take care not to damage the inside of steering
body and piston.

SPYST7034L

5. After the dust cover has been removed from the stub
shaft, back off the adjusting plug about 180 .

NOTE B

Removal of the adjusting plug may cause the bearing

SPYST7036L
to jump out from the valve housing; so, just loosen it.
7. With the piston(B) down, take hold of the housing(C)
and turn the stub shaft(A) to remove the piston.

NOTE
A
At this time, the steel balls installed in the piston and
worm shaft race fall into the piston; therefore, take
care not to let the piston tip up.

SPYST7035L

SPYST7037L
ST -30 STEERING SYSTEM

8. Install the valve housing to the attachment assembly, 10. Place 32 steel balls, which have been in piston in step
in a vise and remove the adjusting plug. (7), into a receiver. Remove the tube clip, pick up the
ball tube with fingers, and shake it lightly off the piston.

NOTE
Adjusting Y-packing Wrench Use utmost care not to lose any of the steel balls.
Valve plug assembly
housing Valve
Threading
recess
O-ring

Attachment

SPYST7038L

9. As shown in Fig, push out the side to which piston was

installed to remove the shaft assembly.

SPYST7040L
NOTE
Ready a receiver to receive the side race, steel balls, 11. Cleaning of parts
and bearing cage which come apart. Wash metallic parts in trichloroethylene or other
cleaning oil.
Replace all rubber parts with new ones; however, if it
housing is a very short time since the parts have been disas-
sembled last and a particular rubber part seems intact
Bearing cage and reusable, clean it with a cloth dampened with al-
cohol or thinner.
Steel balls (18)
NOTE
Side race
Handle with utmost care the sector shaft, piston, rotor,
and worm shaft.

SPYST7039L
POWER STEERING SYSTEM ST -31

REASSEMBLY EEE7DC98

0.9~1.3

1 2 12 13 14 15 16 17 18
0.9~1.3 11 23~25
3 4 5 6 7 8 9 10

19
20

21
22
30~40 23
31 30 29 28 27 26 25 24

1. Taper plug 29. Side race

2. End cap 30. Sealing
3. Sealing 31. O-ring
55 4. O-ring 32. Circulator holder
0.45~0.55 32 33 34 35 36
5. Piston 33. Screw
6. Dowel pin 34. Washer
7. Torsion bar 35. Circulator
8. Worm shaft 36. Steel ball
9. Gear box 37. Dust cover
10. Needle bearing 38. Pitman arm
11. Stub shaft 39. Nut
12. Dowel pin 40. Spring washer
13. Rotor 41. Plain washer
37 38
14. O-ring 42. Oil seal
54
53 15. O-ring 43. Back up ring
52 16. Valve housing 44. Y-packing
12~13 17. Taper plug 45. Needle bearing
18. Bolt & Washer 46. Sector shaft
19. Dust cover 47. Needle bearing
20. Protector 48. Retainer
39 21. Oil seal 49. Y-packing
40 22. Dowel pin 50. Back up ring
41 23. Adjust plug 51. O-ring
51 50 49 48 47 46 45 44 43 42 24. Ball bearing 52. Nut
25. Sealing 53. Adjust screw
26. O-ring 54. Side cover
27. Steel ball 55. Bleed valve
28. Bearing cage (HSX, LDX, LS only)

Tightening Torque : kgf.m

SPYST7041L
ST -32 STEERING SYSTEM

1. Reassembly of sector shaft assembly 2. Reassembly of side cover assembly

1) Pack the adjusting screw mounting hole in the 1) Pack the groove in Y-packing with grease and
sector shaft with grease. Then, insert the adjust- install the Y-packing with its lip facing the needle
ing screw into the hole and tighten the retainer roller bearing.
fully. Next, back it off 180 retorque to 39 Nm (4
kgf.m), then back off 20 again. O-ring
At this time, make sure that the adjusting screw
turns smoothly. Needle roller
bearing Y-packing

Backup ring

Bar
Pack grease

SPYST7044L

2) Correct the bend of backup ring.

SPYST7042L

Insert tool assembly

2) After the retainer has been torqued, stake at two
places.
Insert tool

Squeeze tool

Side cover

SPYST7045L

3. Reassembly of valve housing

Fit O-ring and seal rings into the three grooves in valve
housing I.D. and shape.
SPYST7043L

Seal ring

Insert tool
O-ring
Valve
housing

SPYST7046L
POWER STEERING SYSTEM ST -33

4. Reassembly of adjusting plug and seal assembly 2) Insert the rotor into the space between the stub
shaft and worm shaft so that the straight pin on
1) Press-fit Y-packing into the adjusting plug I.D. the worm shaft fits into the notch in rotor.

2) Pack Y-packing with grease and install the ball

bearing. Rotor

Notch in rotor

Hand press Worm shaft

Straight pin
Y-packing
Press-fit tool

Adjusting plug

SPYST7049L

6. Reassembly of shaft and housing assembly

SPYST7047L
1) Install the bearing cage, steel balls and the side
5. Reassembly of shaft assembly race.

1) Fit it seal ring to the rotor periphery and shape 2) Insert the valve housing, assembled in step 3, to
the seal ring. the worm shaft end.

NOTE
When installing the valve housing, use care not to
Insert tool damage the seal ring inside the housing.

Worm shaft
Seal ring

Rotor

Bearing cage

Steel balls
Guide
SPYST7048L (18)
assembly

Tool assembly

SPYST7050L
ST -34 STEERING SYSTEM

3) Install the valve housing to the attachment as-
sembly, clamped in a vise.
Fit O-ring into an internal groove in the valve
housing and tighten the adjusting plug, then back
off about 180 .
NOTE
• Turn the stub shaft with the valve housing held
in position to make sure that it rotates smoothly
without binding.
• When fitting the O-ring, do not fit it into the thread-
ing recess.
• When installing the adjusting plug, use care not
to damage the Y-packing.
3) Place the piston on a flat base and insert the
shaft and housing assembly into the center hole
in piston.
With the piston ball race position aligned, drop
steel balls through the steel ball hole while rotat-
ing the stub shaft.
NOTE
Pulling the shaft and housing assembly to the extreme
end may result in steel balls dropping out of the ball
race.
Ball tube

Steel ball

Adjusting Y-packing Steel ball

plug
Wrench
Valve housing assembly
Threading Piston
recess
O-ring

Stub shaft

Shaft and housing

Attachment
assembly

SPYST7053L

SPYST7051L
4) Install the ball tube loaded with the steel balls.
7. Installation of piston 4.4 to 5.4 Nm
Ball tube (0.45 to 0.55 kgf·m)
1) Fit O-ring and seal ring into the groove in piston
O.D and shape the seal ring.

2) Pack the inner surfaces of one half of ball tube

with grease and place 10 to 11 balls into it, lining
them up. Then, mate the other half of the ball
tube.

O-ring
Clip
Seal ring

SPYST7054L
Insert tool
Piston

SPYST7052L
POWER STEERING SYSTEM ST -35

5) Apply a force of 49N (5 kgf) to the valve housing 2) Press-fit the oil seal.
as shown to make sure that the diametric play in
the ball screw is 0.5 mm or less. Insert tool assembly

Oil seal
0.5 mm or less

SPYST7057L

9. Overall assembly
SPYST7055L

1) Holding lightly the piston by hand to prevent it

8. Reassembly of steering body
from turning, insert the piston into the body.
1) Fit Y-packing and backup ring into the groove in
the body output shaft hole and shape the backup NOTE
ring.
Use care not to damage the piston seal ring and body
inner surface.
Insert tool assembly

Insert tool
Backup ring

Y-packing

Body

SPYST7056L

SPYST7058L

2) Align oil passages in body with those in valve

housing and secure the valve housing to body.

3) Mate the side cover assembly to the sector

shaft assembly and turn the adjusting bolt
counter-clockwise for tightening.
ST -36 STEERING SYSTEM

4) Tape the sector shaft serration to prevent it from
damaging Y-packing and other parts, then insert
the sector shaft so that its gear is in mesh with
the piston gear at the center.
Wind vinyl
tape
10. Backlash adjustment
1) Install the pitman arm with gears meshing at neu-
tral position.
While moving the pitman arm to and fro by ap-
plying 19.6 N (2kgf) force at its end, measure the
run out of pitman arm at its end with a dial indi-
cator and turn the adjusting screw to obtain the
specified run out value.

2) Move the piston throughout its entire stroke with

the pitman arm to make sure that the piston
moves smoothly.

Dial indicator

Move to and fro

with 19.6 N
(2 kgf) force

SPYST7059L

5) After torquing the side cover to specification,

tighten to specification the plug and seal assem-
bly, which has been backed off 180 in step 6-3).

6) Mount the dust cover to the stub shaft.

SPYST7061L

Wrench assembly
3) After the backlash has been adjusted properly,
apply sealant to the adjusting screw areas to
which lock nut is secured, then torque the lock
nut to specification while securing the adjusting
screw in position.

225 to 245 Nm
(23 to 25 kgf·m)

SPYST7060L

12~13kgf.m

SPYST7062L
POWER STEERING SYSTEM ST -37

POWER STEERING OIL PUMP

COMPONENTS EBEDF1F2

L ...Limit
Rotor and vane sliding
portion ridged wear
L 0.01 mm

2
10
9
8
Flow control valve to
front body clearance 3
L 0.03 mm
20

6 4 Set

11

12
5 14

13
1. Hose connector
2. Plug
3. Flow control valve assembly 16 Turning condition
4. Flow control spring 17
5. Bolt 15 Turning condition
6. Rear body 18
7. Screw 19
8. Pressure plate
9. Cartridge assembly
10. Side plate
11. Straight pin
12. Retaining rind (snap ring)
13. Drive shaft For parts with an encircled number, refer to
14. Retaining ring (snap ring) Disassembly Procedure that follows.
15. Retaining ring (snap ring)
16. Ball bearing NOTE
17. Retaining ring (snap ring) 1. Do not disassemble the flow control valve but reuse
18. Oil seal unless defective.
19. Needle roller bearing 2. Do not remove the oil seal except for replacement.
20. Front body If removed, replace with a new one.

SPYST7078L
ST -38 STEERING SYSTEM

L - ENGINE TYPE

<ZF FN31 Vane pump>

1. Shaft 11. Valve spool

2. Retaining ring 12. Pressure spring
3. Ball bearing 13. Cover
4. Snap ring 14. Pressure plate
5. Shaft seal ring 15. Needle roller
6. Needle sleeve 16. Rotor
7. Housing 17. Pressure plate
8. O-ring 18. Sealing ring
9. Protection screw 19. Backup ring
10. O-ring

SPYST7063L
POWER STEERING SYSTEM ST -39

DISASSEMBLY E41C6FE1 2) Remove the shaft from the ball bearing.

1. Removal of cartridge assembly NOTE

1) Before disassembly, put mating marks on the out- • Never reuse the oil seal once removed.
side with a felt pen, etc. • Use care not to damage the oil seal contact sur-
face.
2) The parts of the cartridge come loose when the
straight pin is removed but befored removing the
vane from the rotor section, put mating marks Hand press
on the side with a felt pen, etc. for reference in
reassembly.
Shaft

NOTE
Ball bearing
The rotor, vane and cam ring have been fitted together
to high precision and utmost care is required when
handling to prevent damage.
When they are to be replaced, therefore, replace as a
cartridge assembly.

SPYST7081L

Pressure plate
3. Removal of needle bearing
Cartridge Remove the needle bearing from front body using
assembly press fit tool.
Side plate

Front body Hand press

Front body

SPYST7079L

2. Removal of shaft

1) Using a plier, remove the retaining ring and re-

move the shaft together with ball bearing from
front body.
SPYST7082L

Plier

Retaining ring

Front body

SPYST7080L
ST -40 STEERING SYSTEM

4. Removal of oil seal 2) Remove valve spool(3) together with compres-

Remove the oil seal tapping the stick. sion spring(4)

NOTE CAUTION
Never reuse the oil seal once removed. Care must be taken as spring will jump out.

Stick

Front body

SPYST7083L
SPYST7064L

L - ENGINE TYPE
2. Removing and dismantling the pressure plate

CAUTION 1) Remove the complete rotor set(2) together with

In order to ensure safe operation of the pump, needle rollers(3)
close attention must be paid on cleanliness dur-
2) Dismantle needle rollers and remove vanes from
ing dismantling and storage of the part. Never
rotor
apply force during the dismantling process which
could, for instance, damage sealing faces, seal- 3) Remove pressure plate
ing surfaces etc.
The resultant damage could lead to partial or total
failure of the pump.

1. Removing the cover

1) Unscrew protecting screw(1) and remove

O-ring(2)

SPYST7065L
POWER STEERING SYSTEM ST -41

3. Removing the shaft 2) Remove O-ring

1) Snap out retaining ring

2) Press out shaft together with ball bearing and

snap ring, retaining ring.

NOTE
Only press out ball bearing if damaged. For this re-
lease the snap ring, retaining ring.

SPYST7068L

SPYST7066L

4. Dismantling the housing

1) If the shaft is damaged in the vicinity of the nee-

dle sleeve bearing surface remove the needle
sleeve.

SPYST7067L
ST -42 STEERING SYSTEM

POWER STEERING OIL RESERVOIR

2
7
3
8
9
4
10

1. Filter cap 5
11
2. Packing
3. Coil spring 12
4. Return filter 6
5. Oil reservoir body 13
6. Inlet pipe
7. Filter cap
8. Packing
9. Oil pipe
10. Oil strainer
11. Plate
12. Collar
13. Outlet pipe

SPYST7069L

INSPECTION EDDC4E1E

1. Due to the danger of swelling it is important that seal-

ing rings and other rubber parts do not come into con-
tact with chlorinated hydrocarbons

2. Check all parts for wear, corrosion, pressure damage

or other faults and decide, whether or not parts are
suitable for re-use.

3. If necessary, re-polish or re-face flange and sealing

surfaces
POWER STEERING SYSTEM ST -43

REASSEMBLY E997B2AD

On the occasion of periodical service, replace the oil seal,

O-ring and other rubber parts using the repair kit.
Referring to the mating marks that have been put at disas-
sembly and paying attention to the rotor direction and the
vane direction of rotation, make reassembly. Check the
rotor and vane turn smoothly and without excessive play.

49~59
(5~6, 36~43) 18~245
(1.8~25, 13~180)

49~59 8
(5~6, 36~43)
5.8~8.8
(0.6~0.9, 4.3~6.5)

Reassembly Sequence
19 18 20 17 13 12 11 10 9 8 7 6 5 4 3 2 1
15 16 14

Tightening Torque : Nm (kgf.m, Ib-ft)

SPYST7084L
ST -44 STEERING SYSTEM

1. Press fitting of oil seal.

Press-fit the oil seal to the front body.
Hand press

Shaft
Hand press
Ball bearing Retaining ring

Oil seal Front body

SPYST7087L

4. Reassembly of shaft
SPYST7085L
1) Assemble the shaft to front body to its position by
2. Press-fitting of needle roller bearing. hand. If necessary, tap with wood hammer.
Press-fit the oil seal to the front body.

Hand press Wood hammer

Bearing Front body

SPYST7088L

SPYST7086L
2) Using a plier, insert the retaining ring to the front
3. Press-fitting of ball bearing. body.
Press-fit the ball bearing to shaft and assemble the
retaining ring.
Plier
NOTE
Be careful not to damage the oil seal contacting sur- Retaining ring
face.
Front body

SPYST7080L
POWER STEERING SYSTEM ST -45

5. Installation of cartridge section. 1. Reassembling the housing

1) Press in the shaft sealing ring up to the stop using

NOTE
tool.
• Install each part, positioning pin hole correctly.
• After installation, tighten with screw.

Pressure plate

Cartridge
assembly
Side plate

Front body

SPYST7070L

SPYST7079L
2) Insert the O-ring

L - ENGINE TYPE

NOTE
So as to guarantee safe operation of the pump, en-
sure the utmost cleanliness during assembly. Do not
use force when assembling components, as this could
lead to damage to sealing ring seats, sealing surfaces
etc. The resultant damage could lead to partial or
complete failure of the pump.
Before assembling the pump thoroughly clean all
parts. Check all parts for wear or other faults and
lubricate them before installation.
It is essential that seals, shaft sealing rings and
O-rings are replaced with new items and that the
SPYST7071L
front faces of the housings and covers are re-drawn
to remove any damage and residues of paint/varnish.
With shaft sealing rings fill the space between the
sealing lip and dust lip with Spectron FO 20 or equiva-
lent Calcium Complex grease of class 2 consistency.
The measuring and setting tools used for the repair
must be subjected to regular calibration checks.
ST -46 STEERING SYSTEM

2. Fitting the shaft 4. Reassembling the cover

1) Press ball bearing on to the shaft up to the stop 1) Fit compression spring and valve spool into the
and secure with the snap ring, retaining ring cover.

2) Screw in the protecting screw with O-ring

2) Press the shaft into the housing up to the stop
and secure with retaining ring
Tightening Torque : 6~7 kgf.m

SPYST7072L
SPYST7074L

3. Reassembling and installing the rotor

NOTE
The following description applies to pumps with clock-
wise rotation. Anti-clockwise rotating pumps must be
assembled mirror-inverted.

1) Fit the pressure plate on to shaft

2) Insert the vanes, with rounded, polished sides

and aligned to the curved ring, into the rotor.

3) Set the complete rotor, with internal chamber to-

wards the housing, on to the shaft.

4) Fit needle rollers in curved ring, pressure plate

and housing.

SPYST7073L
POWER STEERING SYSTEM ST -47

POWER STEERING OIL RESERVOIR

VIEW VIEW

1. Packing 7. Outlet pipe ATTENTION

2. Spring 8. Oil strainer
3. Return filter 9. Body 1. By-pass pressure of filter : 0.5~1.5 kgf.cm²
4. Nut 10. Plate 2. Hydraulic oil : ATF DEXRON ll
5. Packing 11. Filter cap
6. Inlet pipe 12. Oil pipe
13. Packing

SPYST7075L

ADJUSTMENT E8511481

Adjustment of flow control valve assembly relief pressure.

When the flow control valve assembly was disassembled,
make sure that after reassembly the relief pressure is ad-
justed by the following procedures.
Adjust by adding or removing shims. Increase the shim
thickness to reduce the pressure.

Pressure changes by shims

One 0.5mm shim changes pressure approx.
610 kPa (6.2kgf/cm²)
One 0.2mm shim changes pressure approx.
245 kPa (6.2kgf/cm²)

Standard value of valve assembly relief pressure

12.3 MPa (125 kgf/cm2) (Pump speed 2000 rpm)