Exploded View

REMOVAL

LHD Models

1. Steering gear assembly 2. Heat insulator
3. Front suspension member

: Vehicle front
: Always replace after every
disassembly.

: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)

RHD Models

1. Steering gear assembly 2. Heat insulator
3. Front suspension member

: Vehicle front
: Always replace after every
disassembly.

: N·m (kg-m, ft-lb)
: N·m (kg-m, in-lb)

DISASSEMBLY

LHD models

1. Outer socket
2. Boot clamp (small diameter) 3. Boot
4. Boot clamp (large diameter) 5. Steering gear assembly 6. Dust cover

1: Apply Genuine Lithium Soap,
Autorex A (manufactured by Kyodo yushi) or equivalent.

2: Apply Genuine Lithium Soap,
Wanlouver No.2 (manufactured by Kyodo yushi) or equivalent.

: Always replace after every
disassembly.

: N·m (kg-m, ft-lb)

RHD models

1. Outer socket
2. Boot clamp (small diameter) 3. Boot
4. Boot clamp (large diameter) 5. Steering gear assembly 6. Dust cover

1: Apply Genuine Lithium Soap,
Autorex A (manufactured by Kyodo yushi) or equivalent.

2: Apply Genuine Lithium Soap,
Wanlouver No.2 (manufactured by Kyodo yushi) or equivalent.

: Always replace after every
disassembly.

: N·m (kg-m, ft-lb)

Removal and Installation

REMOVAL

1. Set vehicle to the straight-ahead position.

2. Remove intermediate shaft mounting bolt (steering gear assembly side). Refer to ST-10, "Removal and Installation".

CAUTION:
• Spiral cable may be cut if steering wheel turns while separating steering column assembly and steering gear assembly. Always fix the steering wheel using string to avoid turning.

• Place a matching mark on both intermediate shaft and steering gear assembly before removing intermediate shaft.

• When removing intermediate shaft, never insert a tool, such as a screwdriver, into the yoke groove to pull out the intermediate shaft. In case of the violation of the above, replace intermediate shaft with a new one.

3. Remove dash seal from vehicle. Refer to ST-14, "Removal and Installation".

4. Remove tires. Refer to WT-7, "Removal and Installation".

5. Remove steering outer socket from steering knuckle so as not to damage ball joint boot using suitable ball joint remover (commercial service tool).

CAUTION:
Temporarily tighten the nut to prevent damage to threads and to prevent the ball joint remover from sudden drop turning.

6. Remove front suspension member. Refer to FSU-18, "Removal and Installation".

7. Remove steering gear assembly.

INSTALLATION

Note the following, and install in the reverse order of removal.

CAUTION:
Spiral cable may be cut if steering wheel turns while separating steering column assembly and steering gear assembly. Always fix the steering wheel using string to avoid turning.

• Perform final tightening of nuts and bolts on each part under unladen conditions with tires on level ground when removing steering gear assembly. Check wheel alignment. Refer to FSU-7, "Inspection".

• Rotate steering wheel to check for decentered condition, binding, noise or excessive steering effort.

• Never reuse steering outer socket mounting nut and steering gear assembly mounting nut.

• Perform inspection after installation. Refer to ST-21, "Inspection".

Disassembly and Assembly

DISASSEMBLY

1. Loosen outer socket lock nut, and remove outer socket.

CAUTION:
When loosening lock nut, be sure to fix outer socket with a wrench or an equiv

alent.

2. Remove boot clamps, and then remove boot from inner socket.

CAUTION:
Never damage inner socket part and gear housing part of steering gear assembly when removing boot. steering gear assembly must be replaced if steering gear assembly are damaged because it may cause foreign material interfusion.

3. Remove dust cover.

4. Perform inspection after disassembly. Refer to ST-21, "Inspection".

ASSEMBLY

1. Apply recommended grease to the entire inner perimeter (A) of the dust cover lip and contact surface (B) of the gear housing part, and install dust cover to steering gear assembly.

Use Genuine Lithium Soap, Wanlouver No.2 (manufactured by Kyodo yushi) or equivalent

2. Apply recommended grease to inner socket (A) of steering gear assembly and install boot to steering gear assembly.

Use Genuine Lithium Soap, Autorex A (manufactured by Kyodo yushi) or equivalent.

CAUTION

:
Never reuse boot.

Grease application position (Reference) A : 10 mm (0.39 in)

3. Install boot clamp (large diameter) (1) to boot using boot band crimping tool (A) (SST: KV40107300).

CAUTION:
• Never reuse boot clamp (large diameter).

• Install boot clamp (large diameter) (1) securely to boot groove, and crimp it so as to have clearance (B) of 3 mm (0.12 in) or less as shown.

4. Install boot clamp (small diameter) to boot.

CAUTION:
Never reuse boot clamp (small diameter).

5. Adjust inner socket to standard length (L), and then tighten lock nut to the specified torque. Check length again after tightening lock nut.

L : Refer to ST-24, "Inner Socket Length".

CAUTION:
• When tightening the lock nut (1), be sure to fix outer socket (2) with a wrench or an equivalent to prevent the ball joint from getting contact with the knuckle.

• Adjust toe-in. Refer to FSU-7, "Inspection". Length achieved after toe-in adjustment is not necessarily the above value.

Inspection

INSPECTION AFTER INSTALLATION

• Check if steering wheel turns smoothly when it is turned several times fully to the end of the left and right.

• Check the steering wheel play, neutral position steering wheel, steering wheel turning force, and front wheel turning angle. Refer to ST-8, "Inspection".

INSPECTION AFTER DISASSEMBLY

Boot
• Check boot for cracks, and replace it if a malfunction is detected.

Steering Gear Assembly • Check steering gear assembly for damage and scratches. Replace if there are any abnormal conditions.

Outer Socket and Inner Socket • Check the following items and replace the component if it does not meet the standard.

BALL JOINT SWINGING FORCE

• Hook a spring balance at the point shown in the figure and pull the spring balance. Make sure that the spring balance reads the specified value when ball stud and inner socket start to move. Replace outer socket or steering gear assembly (inner socket) if they are outside the standard.

Outer socket
(Measuring point of outer socket: Ball stud upper side) : Refer to ST-23, "Socket Swing Force".

Inner socket
(Measuring point of inner socket: “*” mark shown in the figure) : Refer to ST-23, "Socket Swing Force".

BALL JOINT AXIAL END PLAY

• Apply an axial load of 490 N (50 kg, 110 lb) to ball stud. Using a dial gauge, measure amount of stud movement, and then make sure that the value is within the following specified range. Replace outer socket (1) or steering gear assembly (inner socket) (2) if the measured value is outside the standard.

Outer socket : Refer to ST-24, "Socket Axial End Play".

Inner socket : Refer to ST-24, "Socket Axial End Play".