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STEERING SYSTEM GENERAL ST - 2 SPECIFICATION ST - 6 SERVICE STANDARDS ST - 7 TIGHTENING TORQUE ST - 8 TROUBLESHOOTING ST - 9 SERVICE PROCEDURE ST-14 INTEGRAL POWER STEERING GEAR ST-27 POWER STEERING OIL PUMP ST-37 POWER STEERING OIL TANK ST-43 ST-2 STEERING SYSTEM GENERAL The steering system allows the driver to freely change the traveling direction of the vehicle. The steering force of the steering wheel is transmitted through the steering shaft, power steering gear, pitman arm and drag link to the knuckle arm to steer the vehicle. The system has an integral type power steering gear installed in the gear box to reduce the steering effort. The power steering system hydraulic pressure circuits are as shown below. ECYST01A Oil Tank Oil Pump Power Steering Gear Piping Knuckle arm Power steering oil pump Pitman arm Power steering oil reservoir tank Slave lever Power steering gear 1st drag link 2nd drag link ST-3 ECYST02A Steering Linkage Drag Link Assembly Leaf suspension type : The drag link transmits the force of power steering gear pitman arm to slove lever and knucle arm. Steering Wheel and Shaft The steering shaft is a tlelscopic and tilt type which can by adjusing lock lever select the best driving position by adjusting lock lever. Lock lever Free Lock Telescopic Tilt MA560040 Tie Rod Assembly 1. Leaf suspension type : It connects the laft and right tie-rod arm 2. The connecting point of tie arod and tie rod end is tightened by a left hard bolt at left and a right hand bolt at right. Slave Lever (Leaf-suspension only) The slave lever connects the 1st drag link and 2nd drag by multi- plying the force from 1st drag link to 2nd drag link. Ball joint Spring MA560050 Ball joint Tie rod Tie rod end MA560060 Slave lever 1st drag link 2nd drag link GENERAL ST-4 STEERING SYSTEM 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 clearance. This limits flow of the hydraulic oil to the oil tank and now the hydraulic oil from thr oil pump enters the cylinder chamber A to cause the piston to move to the cylinder chamber B. The hydraulic oil in the cylinder chamber moves, the torsion bar that has been twisted returns to the neutral position. 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 sence of steering response. A left turn is also made on the same operating principles as the right turn but in opposite direction. Integral Power Steering Gear This device consisting of the power cylinder section (output section) that also serves as the steering gear and the control valve section (control section) reduces the power required to operate the steering wheel. Straight Ahead Driving When there is no steering torque from the steering wheel, no relative displacement is caused between the stub shaft and th 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 diffference develops between cylinder chambers A and B so that the piston (ball nut) remains stationay at the neutral position. CYST001C / CYST001D CYST001E/ CYST001F Cylinder chamber B Worm shaft Stub shaft Piston Rotor Cylinder chamber A Torison bar To cylinder chamber B To cylinder chamber A Worm shaft To oil tank To oil tank To cylinder chamber B To cylinder chamber A To oil tank From oil pump From oil pump To cylinder chamber B From oil pump To cylinder chamber A To cylinder chamber B From oil pump To cylinder chamber A To oil tank To cylinder chamber A Worm shaft To oil tank To cylinder chamber B To cylinder chamber A To oil tank From oil pump From oil pump From cylinder chamber B Rotor Rotor Cylinder chamber A Stub shaft Piston Worm shaft Cylinder chamber B Torison bar ST-5 MA560110 MA560120 Delivery stroke Suction stroke Delivery stroke Metering orifice (develops pressure difference P P=P1-P2 Rotor turning direction 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 pro- vided between the stub shaft and worm, allowing manual steering. Power Steering Oil Pump The vanes mounted to the rotor move in and out along the inside surface of the cam ring to cause suction and discharge of the hy- draulic oil. 1. Flow Control Valve This valve causes excess amount of oil to flowback to the oil tank to keep a constant flow of oil to the power steering booster. JMS56-011 Suction stroke Cam ring Vane Rotor Chamber A Pump scution port Flow control spring Spool Chamber B To power steering booster Warm shaft Stub shaft Torsion bar MA560130 Chamber A Chamber B Relief spring Pump scution port Metering orifice 2. Relief Valve This valve keeps a constant hydraulic pressure. As shown right, the flow control valve and the relief valve work together to keep a constant operating pressure. GENERAL ST-6 STEERING SYSTEM SPECIFICATIONS Item Steering wheel Steering shaft type Steering gear type Power steering gear Power steering oil pump Power steering oil reservoir Steering angle (Turning wheel angle) Type O.D (Outer Diameter) Type Cylinder I.D. Stroke Piston operating area (cm 2 ) Oil capacity ( Type Displacement (no load) cc/rev. Controlled flow ( / min) Permissible ratating range rpm Type Capacity ( ) High deck lower deck Specifications Two-spoke type 500 mm Universal joint (with telescopic tilt mechamism) Ball-nut type Intergral type 100 mm 85.6 mm 78.5 12.3 (125) Approx. 1.5 Vane type 20 17 12.2(125) 350 to 3700 Separate from pump 1.8-2.0 45 37 42 35 0° -2° 0° -2° 0° -2° Inner Outer Inner Outer 0° -2° Normal miximum hydraulic pressure MPa (kgf/cm 2 ) Regulated pressure rpm (relief valve) MPa (kgf/cm 2 ) ST-7 Steering wheel play Steering upper shaft SERVICE STANDARDS Unit : mm Steering wheel and shaft Steering linkage Steering gear Integral power sttering booster Power sttering oil pump Nominal value (Basic diameter in [ ]) 15 to 35 0.2 or less 15’ or less 30’ or less [38] 0.015-0.111 [42] 0.045-0.175 38 0.2 to 0.5 39 to 78 (4 to 8) [90] 0.11 - 0.10 to 0.5 [35.5] 0.01 to 0.03 57.97 47.97 - - 10.3 MPa (105 kgf/cm 2 ) - - - - 0.4 0.4 37.9 - - 0.16 0.04 - 0.03 or more 57.87 47.87 0.09 0.03 - Remedy and remarks Adjust Correct or replace assembly Replace assembly Replace assembly Replace Replace Replace Adjust by adjusting screw pitman arm end runout Adjust by adjusting screw Replace Replace Adjust. Replace Replace No deposition, wear of flaw that may catch bar to be tolerated. Replace. No deposition, wear or flaw that may catch bar to be tolerated. Replace as flow control valve assembly or rear body assembly Replace as flow control valve assembly or rear body assembly Play of joint in turning direction (play of needle bearing and spider) Play of yoke spline tube and steering lowershaft (spline shaft) in turning direction Sleeve lever shaft to bushing clearance Connecting link plate to bushing clearance Sector shaft outside diameter Steering gear backlash (Straight ahead position) Worm starting torque after completion of assembly (straight ahead position) Ncm (kgf·cm) Body (cylinder) to ball screw (piston) clearance Ball screw assembly play in axial direction Sttering gear backlash Sleeve to rotor clearance Sector shaft O.D. Ridge wear of pressure plate and side plate rotor and vane sliding portion Flow control valve to rear body clearance Pump relief set pressure (at 1,800 rpm) Maintenance item Limit Play in axial direction (vertical) Pitman arm side Side cover side Packing portion Bearing portion SERVICE STANDARDS ST-8 STEERING SYSTEM TIGHTENING TORQUE Steering shaft Linkage Link and bracket Integral power steering gear Power steering oil pump Steering wheel nut Steering shaft bearing tightening nut (lock plate) Steering shaft yoke bolt Lock plate stopper bolt Worm shaft and yoke attaching bolt Grease nipple Ball stud castle nut Steering shaft mounting Lock lever bolt Steering lever supporting Pitman arm nut Ball tube screw Taper plug Retainer Adjusting screw lock nut Side cover bolt Adjusting plug Valve housing bolt Plug (air breather) Lock ring Plug Cartridge assembly screw Rear body bolt Flow control valve plug Hose connector bolt Oil pump gear mounting bolt Plate screw Thread size Dia. x Pitch mm M20 x 1.5 M52 x 1.5 M10 x 1.25 M5 x 0.8 M20 x 1.25 M6 x 0.75 M20 x 1.5 M12 x 1.25 M8 x 1.25 M12 x 1.25 M36 x 1.5 M6 x 1.0 PT 1/8 M32 x 1.5 M14 x 1.5 M12 x 1.25 M80 x 1.5 M16 x 1.5 M10 x 1.25 M80 x 1.5 M48 x 1.5 - - - - - M6 x 1.0 78 39-69 48-63 3.9-6.4 49-54 3-5 200-340 36 9.8 19.6 390-440 4.4-5.4 8.8-1.3 115-125 54-64 225-245 115-125 6.9-13 295-390 5.9-8.8 49-59 49-59 18-25 88 3.9-4.9 8 4-7 4.9-6.4 0.4-0.65 5.0-5.5 0.3-0.5 20.7-34.5 3.7 1 2 40-45 0.45-0.55 0.9-1.3 12-13 5.5-6.5 23-25 12-13 0.7-1.3 30-40 0.6-0.9 5-6 5-6 1.8-2.5 9 0.4-0.5 Tighten fully, turn back by 180°, tighten again to 39 (4), then turn back by 20° and stake. Tighten to 115 (12) and stake at 2 point Part to be tightened Nm Kgf·m Power steering oil tank ST-9 Probable cause Hard steering Unstable steering because of excessive free play of steering wheel Power steering gear mechanism defective Steering linkage defective Front axle defective Other troubles Power steering gear mechanism defective Steering linkage defective Front axle defective Other troubles Thrust bearing damage Ball of ball screw worn Low fluid level in oil tank Air in oil circuit not completely bled Improper fluid viscosity Trouble in power steering gear system Incorrect pipe connections Defective oil pump (or malfunction) Flow control valve in faulty operation Universal joint abnormally worn, damaged or poorly lubricated Deformed link King pin poorly lubricated Poor front wheel alignments(toe-in, camber, caster) Front wheel tires underinflated Thrust bearing damaged Cargo and passengers are unevenly loaded in the front. Worn rack and gear in ball screw unit Worn bearing in sector shaft Worn ball in ball screw Loose power steering gear mounting bolts Air trapped and air not completely bled Looseness in universal joint Looseness in drag link ball stud Looseness in tie rod end ball stud Worn wheel hub bearing Worn king pin or bushing Uneven brake application TROUBLESHOOTING Replace screw and housing assembly Replace screw and housing assembly Add fluid Bleed air Replace fluid Repair or replace Correct Repair or replace Correct Replace steering shaft assembly or apply grease Replace link Apply grease Correct front wheel alignments In flate as specified value Replace Disperse the load evenly Replace screw and housing sector shaft Replace bearing Replace screw and housing sector shaft Tighten to the specified torque Add fluid, retighten all parts, and bleed air Pack with grease. If the problem still persists, replace steering shaft assembly Replace knuckle arm, pitman arm or drag link Replace tie rod end Replace Replace Readjust or replace lining Symptom Remedy TROUBLESHOOTING ST-10 STEERING SYSTEM Vehicle pulls to one side Steering wheel shimmy Improper wheel alignment Deformed front axle Worn or deformed wheel hub bearing Worn or deformed king pin Steering wheel is off-center Power steering gear defective Broken leaf spring Uneven brake application Right and left tires unevenly inflated Right and left tires greatly different in the degree of wear Right and left tires different in axial distance Bent rear axle housing Excessive clearance between king pin and bushing Worn or deteriorated wheel hub bearing Improper wheel alignment (particularly camber and caster) Looseness in knuckle arm or tie rod ball stud Excessively uneven tire pressure Knuckle arm, tie rod arm, backing plate and nuckle, etc. Improperly tightened U-bolt, nut, etc. of front spring loose Lateral and radial runouts of front tires, and ncorrect static and dynamic balance Improper play in ball screw unit and sector shaft Worn thrust bearing Defective power steering booster Looseness in ball stud of drag link Worn sector shaft and bearing Worn ball and groove in ball screw Excessive runout of propeller shaft Reduction pinion and gear damaged and in poor tooth contact Excessive tire runout Correct Replace Replace Replace king pin or bushing Correct Correct or replace Replace Repair Inflate properly Replace tires Correct axial distance Replace axle housing Replace king pin or bushing Replace Correct wheel alignment Replace knuckle arm or tie rod end Adjust tire pressure Tighten to specified torque Tighten to specified torque Correct wheel balance Adjust Replace Correct or replace Replace knuckle arm, pitman arm or drag link Replace sector shaft and bearing Replace screw and housing assembly Correct or replace Replace pinion and gear or correct tooth contact Repair or replace Front axle steering system defective Other troubles Front axle assembly defective Power steering system defective Other troubles Probable causeSymptom Remedy [...]... set and clutch are securely fixed Lever and clutch set Free position Set position Lock lever JJR56-021 SERVICE PROCEDURE Steering Linkage ST-21 Drag Link 1 Removal Straighten the end of split pin of the drag link, pinch the split pin head with pliers and remove the split pin, remove the nut, then remove the drag link CAUTION: • Pitman arm 1st drag link Nut Split pin ... Installation Torque the nut to specification and fit a new split pin into position STEERING SYSTEM 7 After installation, check and adjust toe-in Pitman arm 1st drag link Nut Split pin 2nd drag link Nut 1st drag link Slave lever Knuckle arm 2nd drag link Nut Split pin ECYST03A SERVICE PROCEDURE ST-23 Tir rod 1 Removal Split pin Tie rod arm Tie rod Nut... mating mark on spline shaft and spline tube 2) Remove the dust cover from the end of column and remove the support attaching bolt 3) Remove the lever and clutch set attaching bolt 4) Pull the upper and lower shaft assembly up and remove 7 Support the column end with vice Upper and lower shaft assembly Lever and clutch set attaching bolt Column and attaching bolt Dust cover Spline shaft Spline tube MA560170... 11 8 26 15 23 22 17 21 1 2 3 4 5 6 7 8 9 10 11 12 13 Locker lever bolt Plain washer Locker lever Locker lever nut Washer Spring Washer Bolt Nut Spring washer Clutch Lever and clutch set Collar 14 15 16 17 18 19 20 21 22 23 24 25 26 Spring Snap pin Clevis pin Snap pin Clevis pin Nut Spring washer Bolt Lever Wave washer Collar Protector Steering column bracket MA560270 ST-20 STEERING SYSTEM Reassembly... Disassembly, Inspection and Adjustment 1 Axial play of steering shaft to column NV 0.2mm or less 4 3 2 5 6 7 Joint play in rotating direction NV less than 15' 8 * Be sure make an mating mark at each joint before disassembly Joint play in rotating direction NV less than 15' in angle Spline shaft joint play in rotating direction NV than 15' in angle Disassembly 1 Steering upper shaft assembly 2 Spline shaft... 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 oil pump Disassemble, check and replace if defective • Defective gasket, oil seal Disassemble, check and replace if defective • Loose bolts Fluid leaks from Retighten to specified torque... leaks from Retighten to specified torque • Fluid leaks from oil tank due to overfilling Adjust to specified level • Fluid leaks from oil tank due to trapped air Bleed air and adjust to specified oil tank level • Improperly welded pipes Braze or replace • Loose hydraulic piping and connections Retighten to specified torque or replace ST-14 STEERING SYSTEM SERVICE PROCEDURE Removal and Installation 78... Pitman arm 1st drag link Nut Split pin 2nd drag link Do not reuse the split pin once removed Nut 1st drag link Slave lever Knuckle arm 2nd drag link Nut Split pin ECYST03A 2 Disassembly Dust cover NOTE : • Do not disassemble the drag link as it is nonmaintainable Drag link 3 Inspection of ball stud 1) Move the ball stud section up and down and right and left to check... defective Improper fluid in power steering system Replace with the specified hydraulic fluid ST-12 STEERING SYSTEM Symptom Probable cause Remedy Steering wheel Problems not in Uneven tire pressure Adjust to specified pressure oscilations power steering Incorrect front wheel alignment Measure wheel alignment If incorrect, adjust to specified value ront wheels out of balance Rebalance with wheel balancer... (molybdenum desulfide base grease) Apply grease (molybdenum desulfide base grease) Reinforcement ring End holder JMS56-071 SERVICE PROCEDURE ST-25 6 Installation Tightening the nut to specification and install a new split pin Split pin Tie rod arm Tie rod Nut JMS56-072 7 After installation, check and ajust toe-in ST-26 STEERING SYSTEM Slave Lever Arm Bracket Assembly Ball joint 2nd drag link 1st drag link