STEERING GEAR AND LINKAGE ASSEMBLY

id061300802100

Special Service Tool (SST)

49 B032 317
 
Bearing & oil seal remover
49 T028 301
 
Dust boot installer
49 JP02 001
 
Adjustable wrench
49 T025 001
 
Boot clamp crimpers
—
—

Caution
•  To prevent damage to the steering gear, secure it to the vise using a copper plate or clean cloth.

1.  Assemble in the order shown in the figure.

2.  Install the steering gear and linkage. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

L.H.D.

ac9wzw00005267

R.H.D.

ac9wzw00003546

1
Steering gear
2
Mounting rubber
(See Mounting Rubber Assembly Note.)
3
Tie Rod
(See Tie Rod Assembly Note.)
4
Boot
5
Boot band
(See Boot Band Assembly Note.)
6
Boot clamp
7
Locknut
8
Tie-rod end
(See Tie-rod End Assembly Note.)
9
Dust cover

Mounting Rubber Assembly Note

1.  Apply soapy water to the rubber part of the mounting rubber.

2.  Press fit the ear portion of the mounting rubber (lower side) using the SSTs until it projects from the gear housing as shown in the figure.

ac9uuw00006226
Note
•  Press fit the ear portion of the mounting rubber (upper side) until it partially enters the gear housing.

3.  Reverse the gear housing, then press fit the mounting rubber using the SSTs and the press until the mounting rubber ear portion (upper side) contacts the gear housing.

ac9uuw00006227

4.  Verify that both mounting rubber ears are correctly assembled with no gaps between them and the gear housing as shown in the figure.

ac9uuw00006228
•  If there are gaps, readjust their positions using the SSTs and the press.


Tie Rod Assembly Note

1.  Install the SST to the torque wrench as shown in the figure, set it on the tie rod, and measure dimensions A and L shown in the figure.

adejjw00015170

2.  Tighten the tie rod after calculating the tightening torque using the following formula.

ac9uuw00006229
Tightening torque
100—110 N·m {10.2—11.2 kgf·m, 74—81 ft·lbf}
Calculation formula
T×(L/A)
T: Tightening torque (100—110 N·m {10.2—11.2 kgf·m, 74—81 ft·lbf}
L: Torque wrench effective length
A: Length from center of tie rod to grip


Boot Band Assembly Note

1.  Assemble the boot band to the boot.

2.  Crimp the boot band using the SST.

ac9uuw00006230

3.  Verify that the crimping clearance A is within the specification.

Standard clearance A
1.5—2.5 mm {0.060—0.098 in}
•  If crimping clearance A exceeds the specification, reduce SST clearance, and crimp the boot band again.
•  If crimping clearance A is less than the specification, increase SST clearance, and crimp a new boot band.

4.  Rotate the by hand and verify that it is securely installed to the boot band.


Tie-rod End Assembly Note

1.  Align the marks that were made before removing the tie-rod end, and assemble the tie-rod end to the tie rod.

ac9uuw00006231
Note
•  When newly replacing a tie-rod end, place alignment marks on the new part in the same position as the remove tie-rod end.
ac9uuw00006232

2.  Verify that dimension A shown in the figure is within the specification.

ac9uuw00006233
Specification
8.9—21.9 mm {0.36—0.86 in}
•  If not within the specification, make adjustments so that dimension A is within the specification.