| TIBURON(GK) >2006 > G 2.0 DOHC > Steering System > Hydraulic Power Steering System > Power Steering Gear Box>Repair procedures |

REMOVAL
1. | Detach the power steering pressure hose mounting clamp and the return tube mounting clamp.
2. | Drain the power steering fluid.
3. | Disconnect the pressure tube and the return tube fittings from the gear box.
4. | Disconnect the shaft assembly from the gear box inside the passenger compartment.
5. | Remove the strap and push out the dust cover and remove the dust cover mounting plate.
6. | Raise up the vehicle.
7. | Remove the front tires (RH/LH).
8. | After removing the split pin, disconnect the tie rod from the knuckle by using the special tool (09568-31000).
9. | Remove the stabilizer bar (RH side) mounting bracket and link nut.
10. | After removing the rear roll stopper bracket mounting bolt from the sub frame, remove the rear roll stopper.
11. | After loosing the sub frame mounting bolts a little so as to be the sub frame assembly hung down slightly.
12. | Remove the power steering gear box mounting bolts, pressure tube and the return tube clamp.
13. | Pull the power steering gear box assembly toward the right side of the vehicle.
When removing the gear box, pull it out carefully and slowly to avoid damaging.
INSTALLATION
1. | Push in the power steering gear box assembly in the right side of the vehicle.
2. | Install the dust cover mounting plate.
3. | Connect the dust cover to its mounting plate with a new strap.
4. | Connect the steering gear box assembly to the steering column and shaft assembly.
5. | Installation is the reverse of removal.
6. | After installation, bleed the system.
DISASSEMBLY
1. | Remove the tie rod end from the tie rod.
2. | After mounting the tie rod end in a vise, remove the dust cover from the ball joint.
3. | Remove the bellows band.
4. | Remove the bellows clip.
5. | Pull the bellows out toward the tie rod.
Check for rust on the rack when the bellows are replaced.
6. | Remove the feed tube from the rack housing.
7. | While moving the rack slowly, drain the fluid from the rack housing.
8. | Unstake the tab washer which fixes the tie rod and rack with a chisel.
9. | Remove the tie rod from the rack.
Remove the tie rod from the rack, taking care not to twist the rack.
10. | Remove the yoke plug locking nut.
11. | Remove the yoke plug with a 14mm socket.
12. | Remove the lock nut, yoke plug, rack support spring, rack support yoke and bushing from the gear box.
13. | Remove the valve body housing by loosening the two bolts.
14. | Turn the rack stopper clockwise until the end of the circlip comes out of the slot in the rack housing.
15. | When the end of the circlip comes out of the notched hole of the housing rack cylinder, turn the rack stopper counterclockwise and remove thecirclip.
Be careful not to damage the rack.
16. | Remove the rack stopper, rack bushing and rack from the rack housing.
17. | Remove the O-ring from the rack bushing.
18. | Remove the oil seal from the rack bushing.
19. | Remove the valve body from the valve body housing with a soft hammer.
20. | Using the special tool, remove the oil seal and ball bearing from the valve body housing.
21. | Remove the oil seal and O-ring from the rack housing.
Be careful not to damage the pinion valve cylinder bore of the rack housing.
22. | Using the special tool, remove the oil seal from the rack housing.
Be careful not to damage the rack cylinder bore of the rack housing.
INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY
When mounting the gear box in a vise, let the installation section of it be fixed to the jaws. If other section is fixed, the gear box may be damaged.
TOTAL PINION PRELOAD
1. | Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload.
Standard value Total pinion preload : 0.6~1.3 Nm (6~13 kg•cm, 0.4~1.0 lb•ft)
Measure the pinion preload through the entire stroke of the rack.
2. | If the measured value is out of specifications, first adjust the yoke plug, then recheck the total pinion preload.
3. | If not obtain the total pinion preload after adjusting the yoke plug check or replace the yoke plug components.
TIE ROD SWING RESISTANCE
1. | Rotate the tie rod severely ten times.
2. | Measure the tie rod swing resistance with a spring scale.
Standard value Total rod swing resistance : 2~5 Nm (20~50 kg•cm, 1.4~3.6 lb•ft)
3. | If the measured value exceeds the standard value, replace the tie rod assembly.
Even if the measured value is below the standard value, the tie rod that swings smoothly without excessive play may be used. If the measuredvalue is below 0.44 kg•cm, replace the tie rod.
BELLOWS INSPECTION
1. | Inspect the bellows for damage or deterioration.
2. | Make sure the bellows are secured in the correct position.
3. | If the bellows are defective, replace them with new ones.
REASSEMBLY
1. | Apply the specified fluid to the entire surface of the rack oil seal.
Recommended fluid : PSF-3
2. | Install the oil seal to the specified position in the rack housing.
3. | Apply the specified fluid to the entire surface of the rack bushing oil seal.
Recommended fluid : PSF-3
4. | Install the oil seal in the rack bushing.
5. | Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
6. | Apply the specified grease to the rack teeth.
Recommended grease Multipurpose grease SAE J310a, NLGI #2 EP
Do not plug the vent hole in the rack with grease.
7. | Insert the rack into the rack housing and install the rack bushing and rack stopper.
8. | Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing. Install the circlip while turning the rack stopper.
The circlip end should not be visible through the notched hole of the rack housing.
9. | Using a special tool, install the oil seal and the ball bearing in the valve body housing.
10. | After applying the specified fluid and grease to the pinion valve assembly, install it in the rack housing assembly.
11. | After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly and O-ring in the gear box.
12. | Install the tab washer and the tie rod and stake the tab washer end at two points over the tie rod.
13. | Install the bushing, rack support yoke, rack support spring and yoke plug in the order shown in the illustration. Apply semi-drying sealantto the threaded section of the yoke plug before installation.
14. | With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to 12 Nm (120 kg•cm, 8.9 lb•ft), with a 14mm socket. Loosen the yoke plug approximately from 30° to 60°and tighten the yoke nut to the specified torque.
Tightening torque 50~70 Nm (500~700 kg•cm, 37~52 lb•ft)
15. | Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
16. | Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.
Silicone grease
17. | Install the new attaching band to the bellows.
When the bellows are installed, a new band must be used.
18. | Install the bellows in position, taking care not to twist it.
19. | Fill the dust cover inner side and lip with the specified grease, and fix the dust cover in position with the clip ring attached in the grooveof the tie rod end.
Recommended grease A : POLY LUB GLY 801K or equivalent B : SHOWA SUNLIGHT MB2 or equivalent Dust cover inner side and lip : THREE BOND
20. | Install the tie rods so that the length of the left and right tie rods equals the standard value.
Standard value Tie rod free length : 204.5mm
21. | Check for total pinion preload.
INSPECTION AND ADJUSTMENT BEFORE DISASSEMBLY
When mounting the gear box in a vise, let the installation section of it be fixed to the jaws. If other section is fixed, the gear box may be damaged.
TOTAL PINION PRELOAD
1. | Rotate the pinion gear for approximately 4 to 6 seconds for one rotation to measure the total pinion preload.
Standard value Total pinion preload : 0.6~1.3 Nm (6~13 kg•cm, 0.4~1.0 lb•ft)
Measure the pinion preload through the entire stroke of the rack.
2. | If the measured value is out of specifications, first adjust the yoke plug, then recheck the total pinion preload.
3. | If not obtain the total pinion preload after adjusting the yoke plug check or replace the yoke plug components.
TIE ROD SWING RESISTANCE
1. | Rotate the tie rod severely ten times.
2. | Measure the tie rod swing resistance with a spring scale.
Standard value Total rod swing resistance : 2~5 Nm (20~50 kg•cm, 1.4~3.6 lb•ft)
3. | If the measured value exceeds the standard value, replace the tie rod assembly.
Even if the measured value is below the standard value, the tie rod that swings smoothly without excessive play may be used. If the measuredvalue is below 0.44 kg•cm, replace the tie rod.
BELLOWS INSPECTION
1. | Inspect the bellows for damage or deterioration.
2. | Make sure the bellows are secured in the correct position.
3. | If the bellows are defective, replace them with new ones.