Group 37 Steering - JustAnswer · PDF fileFaulty power steering mechanism ... Difference excessive in degree of wear ... Power steering system fluid pressure (with hands off

Steering

Group 37

Pub.No.TWME0709-37

37-1

INDEX

SPECIFICATIONS ............................................................................. 37-2

STRUCTURE AND OPERATION 1. Steering System .......................................................................... 37-42. Fluid Flow ................................................................................... 37-43. Power Steering Booster .............................................................. 37-54. Power Steering Oil Pump ............................................................ 37-7

TROUBLESHOOTING ..................................................................... 37-10

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Change of Power Steering Fluid ................................................ 37-142. Bleeding of Power Steering System .......................................... 37-153. Performance Verification Test of Power Steering System .......... 37-164. Steering Wheel Play .................................................................. 37-175. Steering Column Looseness ..................................................... 37-176. Inspection of Drag Link Ball Joint ............................................. 37-17

STEERING COLUMN ...................................................................... 37-18

POWER STEERING BOOSTER AND DRAG LINK .......................... 37-24

POWER STEERING OIL PUMP<FK> .................................................................................................. 37-48<FM> .................................................................................................. 37-52

POWER STEERING OIL TANK ........................................................ 37-58

37-2

Steering wheel, steering shaft and power steering booster

Power steering oil pump

ItemSpecifications

FK61 FK62, FK65 FM

Steering wheelType 4-spoke type

Outer diametermm {in.} 450 {17.7}

Steering shaft Type Universal joint type (tilt and telescopic type)

Power steering booster

Manufacturer Unisia JKC Steering System

Type Ball nut type

Form Integral type

Gear ratio 17.1 to 20 18.0 to 19.9 22.4

Cylinder diametermm {in.} 85 {3.35} 90 {3.54} 100 {3.94}

ItemSpecifications

FK61 FK62, FK65 FM

Manufacturer KYB Unisia JKC Steering System

Type Vane type

Delivery rate cm3 {cu.in.}/rev. 13.6 {0.83} 17.5 {17.5}

Adjusted flow volume dm3 {qts}/min. 11 to 13 {12 to 14} 18 {19}

Adjusted pressure (relief valve)MPa {psi, kgf/cm2}

13.7

{1990 , 140 }

12.3

{1780 , 125 }

13.7

{1990 , 140 }

Permissible revolutions rpm 600 to 4500 600 to 4000

+0.5–0.2

+71–28

+5–2

+0.5–0.2

+71–28

+5–2

0–0.69

0–100

0–7

SPECIFICATIONS

M E M O

37-3

37

37-4

1. Steering System

2. Fluid Flow

STRUCTURE AND OPERATION

37

37-5

3. Power Steering Booster

• A rotary valve is adopted for the valve, the center of the power steering. For steering reaction force and return ofthe valve, the valve operates lightly and smoothly at low speed by means of the torsion bar, and provides stablesteering feel up to high speed.

37-6

3.1 When moving straight forward• As equal pressure is applied to cylinder chambers A and B on

both sides of the piston, the piston is placed in neutral position.

3.2 When turning the steering wheel• When the steering wheel is turned, the stub shaft is twisted,

which causes the rotor to shut off oil supply passages to cylinderchamber B. As a result, pressure difference is caused betweencylinder chamber A and cylinder chamber B, and the pistonmoves, facilitating rotation of the worm shaft. The illustration shows a condition when the steering wheel isturned to the left.

3.3 When hydraulic circuit fails• The turning force of the stub shaft alone turns the worm shaft.


37

37-7

4. Power Steering Oil Pump

37-8

4.1 Flow control valve(1) Operation of flow control valve as-

sembly(1.1) When not functioning (oil pump

in operation at low speed)• Oil pressure in the chamber A is weak-

er than the combined force of oil pres-sure in the chamber B and tension ofthe flow control spring, and the flowcontrol valve remains stationary.

(1.2) When functioning (oil pump inoperation at middle to highspeeds)

• Oil pressure in the chamber A over-comes the combined force of oil pres-sure in the chamber B and tension ofthe flow control spring, and the flowcontrol valve is shifted.

• Port is made open to release oil pres-sure, and the flow rate from the cham-ber A is maintained constant.


37

37-9

(2) Operation of relief valve• When the combined force of oil pres-

sure in the chamber B and tension ofthe flow control spring overcomes oilpressure in the chamber A, the flowcontrol valve is shifted. Further in-creased oil pressure in the chamber Bpushes the relief valve to open port,thus preventing excessive oil pressurefrom going to the chamber C.

37-10

Symptoms

Stee

ring

whe

el h

eavy

to o

pera

te

Stee

ring

whe

el p

lay

exce

ssiv

e an

d un

stab

le

Stee

ring

whe

el p

ulle

d to

one

sid

e

Stee

ring

shim

my

Stee

ring

whe

el re

turn

not

sm

ooth

Stee

ring

whe

el d

oes

not t

urn

Stee

ring

angl

e no

t eno

ugh

or d

iffer

ent

betw

een

right

and

left

Oil

leak

age

Oil

pum

p oi

l pre

ssur

e ab

norm

al

Noi

se fr

om o

il pu

mp

(grin

ding

)

Noi

se fr

om o

il pu

mp

(squ

eaki

ng)

Noi

se fr

om o

il pu

mp

(low

whi

rring

)

Reference Gr

Possible causes

Faul

ty p

ower

ste

erin

g m

echa

nism

Thrust bearing damaged or worn O O O

Ball and groove of ball screw worn O O O

Air bleeding insufficient O

Hydraulic fluid viscosity unsuitable O

Power steering booster system faulty O

Operation of flow control valve faulty O

Rack and gear of ball screw unit worn O

Bearing of sector shaft worn O O

Power steering booster mounting bolts and nuts loose O

Play between ball screw unit and sector shaft unsuitable O

Valve control edge damaged, or seal ring and O-ring for control broken O

Hydraulic fluid in power steering system faulty O

Adjustment of rack engagement turning torque faulty O O

Hydraulic circuit clogged O O

Sector shaft gear worn O

Stub shaft serration damaged or worn O

Power steering booster unit faulty O O

O-ring and oil seal faulty O

Application of sealant faulty O

Faul

ty s

teer

ing

colu

mn

and

link

mec

hani

sm

Universal joint abnormally worn or dam-aged, or poorly greased O O

Link deformed O

Drag link ball stud loosened O O

Tie rod end ball stud loosened O O

Tie rod bent O

Pitman arm mounting position incorrect O

Right and left turning center of steering wheel displaced O

TROUBLESHOOTING

37

37-11

Symptoms

Stee

ring

whe

el h

eavy

to o

pera

te

Stee

ring

whe

el p

lay

exce

ssiv

e an

d un

stab

le

Stee

ring

whe

el p

ulle

d to

one

sid

e

Stee

ring

shim

my

Stee

ring

whe

el re

turn

not

sm

ooth

Stee

ring

whe

el d

oes

not t

urn

Stee

ring

angl

e no

t eno

ugh

or d

iffer

ent

betw

een

right

and

left

Oil

leak

age

Oil

pum

p oi

l pre

ssur

e ab

norm

al

Noi

se fr

om o

il pu

mp

(grin

ding

)

Noi

se fr

om o

il pu

mp

(squ

eaki

ng)

Noi

se fr

om o

il pu

mp

(low

whi

rring

)

Reference Gr

Possible causes

Faul

ty fr

ont a

xle,

etc

King pin poorly greased O O

Gr26

Front wheel alignment (toe-in, camber and caster) incorrect O O O O

Thrust bearing damaged O

Wheel hub bearing worn out or damaged O O O

King pin or bushing worn out or damaged O O O

Front axle deformed O

Knuckle arm, tie rod arm, knuckle, etc. im-properly tightened O

Front spring U-bolt, nut, etc. loose O Gr33

King pin bearing poorly greased O O

Gr26

King pin bearing worn out or damaged O O O

Front axle parts overtightened O

Steering angle incorrectly adjusted O O

Mounted parts, connections loose O

Knuckle stopper bolt improperly adjusted O

Faul

ty o

il pu

mp

Oil pump body faulty O

O-ring, oil seal faulty O

Bolt improperly tightened O

Maximum generated oil pressure insuffi-cient O

Oil line crushed or clogged O

Air caught in oil pump O

Oil pump interior seized O O O

Mounting bolt and nut loose O

Pump body faulty O

Valve malfunctioning O

37-12

Symptoms

Stee

ring

whe

el h

eavy

to o

pera

te

Stee

ring

whe

el p

lay

exce

ssiv

e an

d un

stab

le

Stee

ring

whe

el p

ulle

d to

one

sid

e

Stee

ring

shim

my

Stee

ring

whe

el re

turn

not

sm

ooth

Stee

ring

whe

el d

oes

not t

urn

Stee

ring

angl

e no

t eno

ugh

or d

iffer

ent

betw

een

right

and

left

Oil

leak

age

Oil

pum

p oi

l pre

ssur

e ab

norm

al

Noi

se fr

om o

il pu

mp

(grin

ding

)

Noi

se fr

om o

il pu

mp

(squ

eaki

ng)

Noi

se fr

om o

il pu

mp

(low

whi

rring

)

Reference Gr

Possible causes

Oth

er a

bnor

mal

ities

Load excessive forward of load-carrying platform O

Load excessive rearward of load-carrying platform O

Load excessive on one side of loading bed O

Difference excessive in wheelbase be-tween left and right O

Propeller shaft runout excessive O Gr25

Front axle bent O Gr26

Rear axle housing bent O Gr27

Final drive gear and final drive pinion damaged or improperly engaged O Gr27

Tire pressure insufficient O

Gr31

Tire pressure excessive O

Difference excessive in degree of wear between left and right tires O

Left and right tires different in outer diam-eter O

Front tire radial and lateral runout, static and dynamic balance incorrect O

Braking force unbalanced O Gr35

Oil leakage from oil tank due to filling be-yond capacity O

Oil leakage from oil tank due to air caught inside O

TROUBLESHOOTING

M E M O

37-13

37

37-14

1. Change of Power Steering FluidLubricant and/or sealant

1.1 Draining• Jack up the front wheels.• Loosen feed and return pipes connected to the power steering

booster.

CAUTION• When removing the feed pipe and return pipe, clean the port

area to prevent ingress of dirt and dust.

• Repeatedly turn the steering wheel fully left and right to drain thehydraulic fluid from the power steering booster, and then tightenthe feed pipe and return pipe.

1.2 Filling• Pour fluid into the power steering oil tank up to the bottom of the

filler cap.• Bleed the power steering system of air.

Mark Points of application Specified lubricant and/or sealant Quantity

– Power steering oil tank Automatic transmission fluid (DEXRON II or DEXRON III type)

Between MIN and MAX of

power steering oil tank

ON-VEHICLE INSPECTION AND ADJUSTMENT

37

37-15

2. Bleeding of Power Steering SystemLubricant and/or sealant

• Pour fluid to the power steering oil tank up to the bottom of thefiller cap.

• With the engine stopped, jack up the front wheels.• Repeatedly turn the steering wheel fully left and right. When the

fluid level has dropped, add fluid enough to maintain the fluidlevel within the specified range.

• Start the engine to idle.• When the fluid level has dropped, stop the engine and add fluid.• Restart the engine. While checking for a drop in the fluid level,

repeatedly replenish the hydraulic fluid until the fluid level is sta-bilized.

CAUTION• To avoid seizure of the power steering oil pump, do not

keep the steering wheel turned fully to left or right for morethan 15 seconds when the engine is running.

• If there is any abnormal noise or a fluid level fluctuation, airshould be still trapped in the power steering system. Turn thesteering wheel several times to raise the fluid temperature to ap-proximately 60 to 80°C {140 to 176°F}.

• Stop the engine and wait for approximately five minutes.• Lower the front wheels and turn the steering wheel several

times. If there is no noise or fluid level fluctuation, the bleeding ofthe power steering system is completed.

• When air bleeding is completed, check the fluid level in the oiltank, and pipe and hose connections for fluid leaks.


– Power steering oil tank Automatic transmission fluid (DEXRON II or DEXRON III type)

Between MIN and MAX of

power steering oil tank

37-16

3. Performance Verification Test of Power Steering SystemService standards

*a: Check the power steering booster and hydraulic circuit for clogging.

• Perform the tests with the following measuring conditions to ver-ify normal operation of the power steering booster and powersteering oil pump.• Install oil pressure gauge capable of measuring upward of

14.7 MPa {2130 psi, 150 kgf/cm2} and stop valve betweenpower steering oil pump and power steering booster, thenbleed air.

• Start engine to idle.• Turn steering wheel left and right several times to raise fluid

temperature up to 50 to 60°C {122 to 140°F}.• With the engine idling, fully open stop valve.

CAUTION• To avoid seizure of the power steering oil pump, never

close the stop valve for more than 15 seconds.

Location Maintenance item Standard value Limit Remedy

– Power steering system fluid pressure (with hands off steering wheel)

490 kPa {71 psi, 5 kgf/cm2} or less – Repair*a

– Relief set pressure (measure with stop valve tightened at engine idle)

FK6113.7 MPa

{1990 psi, 140 kgf/cm2}

– ReplaceExceptFK61

12.3 MPa{1780 psi, 125 kgf/

cm2}

Test item Test procedure Judging standard

Verification of smooth operation • Jack up front wheels and turn steering wheel fully left and right. Smooth operation

throughout test

Measurement of fluid pressure in power steering system

• Measure fluid pressure with hands off steering wheel. Must be at speci-fied value or less

Measurement of relief set pressure

• Measure maximum fluid pressure with the stop valve tightened at engine idle.

• Do not close stop valve for longer than 15 seconds.

Must not be out of specified value

+0.5–0.2

+71–28

+5–2

+0.5–0.2

+71–28

+5–2

ON-VEHICLE INSPECTION AND ADJUSTMENT

37

37-17

4. Steering Wheel PlayService standards (Unit: mm {in.})

• With the vehicle placed straight forward, start the engine andgently turn the steering wheel right and left to measure its pe-ripheral play.

• If the play deviates from the standard value, check tighteningpoints and backlash of the power steering booster.

5. Steering Column Looseness• Push and pull the steering wheel by hand to check the steering

column for looseness.• With the steering column tilted all the way forward, pull the steer-

ing wheel backward and check the steering column for loose-ness.

• If the steering column is loose, adjust the tilting and telescopinglever.

6. Inspection of Drag Link Ball Joint(1) Backlash• With the vehicle in the stationary state, hold the rod of the drag

link and move it in the forward, backward, vertical and lateral di-rections of the vehicle and check for play at the ball joints. Besure to check the power steering booster and ball joints on bothsides of the knuckle arm.

• If play is excessive, replace the drag link.

(2) Dust cover• Check the dust cover for wear, cracks and other damage.• If there is any abnormality, replace the dust cover.


– Steering wheel play 10 to 40 {0.39 to 1.57} – Adjust

37-18

STEERING COLUMN

37

37-19

Removal sequence

Installation sequenceFollow the removal sequence in reverse.

Service standards (Unit: mm {in.})

Tightening torque (Unit: N·m {ft.lbs, kgf·m})

Lubricant and/or sealant

Special tools (Unit: mm)


13 Steering column

Play in joint rotation direc-tion 15 or less

– ReplacePlay in steering shaft axial direction 0.2 {0.0079} or less

Mark Parts to be tightened Tightening torque Remarks

Bolt (horn pad mounting) 7.0 to 11 {5.2 to 8.1, 0.7 to 1.1} –

Nut (steering wheel mounting) 68 to 78 {50 to 58, 6.9 to 8.0} –

Screw (combination switch mounting) 2.5 ± 0.5 {1.8 ± 0.4, 0.3 ± 0.1} –

Twist-off bolt (starter switch mounting) 13 to 15 {9.6 to 11, 1.3 to 1.5} –

Nut (steering column and power steering booster mounting) 51.45 ± 2.45 {38 ± 1.8, 5.2 ± 0.2} –

Bolt (steering column mounting) 17 to 26 {13 to 19, 1.7 to 2.7} –

Nut (steering column mounting) 9 to 14 {6.6 to 10, 0.9 to 1.4} –


Horn contact ring on combination switch side Wheel bearing grease [NLGI No. 2 (Li soap)] As required

Mark Tool name and shape Part No. Application

MH062421 Removal of steering wheel

1 Horn pad2 Steering wheel3 Shaft rear cover4 Shaft front cover5 Grommet6 Combination switch

7 Twist-off bolt8 Bracket9 Starter switch

10 Harness cover11 Support12 Dust cover

13 Steering column (See later section.)

*a: Power steering booster: Non-reusable parts

Steering wheel puller

A B

M10 × 1.25 M14 × 1.5

37-20

Work before removalAlignment mark: Steering column and power steeringbooster

• Provide alignment marks on the steering column and powersteering booster.

Removal procedureRemoval: Steering wheel

• After removing the steering wheel mounting nut, be sure to putalignment marks on the steering wheel and steering shaft.

Removal: Starter switch• Drill a hole of 5.5 to 6 mm {0.22 to 0.24 in.} in diameter to a

depth of 10 to 15 mm {0.39 to 0.59 in.} in the twist-off bolt.• Using the drilled hole, screw the screw extractor counterclock-

wise into the twist-off bolt and remove it.

STEERING COLUMN

37

37-21

Installation procedureInstallation: Starter switch

• Install the starter switch using new twist-off bolts.• Twist off the bolt head of the twist-off bolt.• Check for operation of the steering lock function of the starter

switch.

Installation: Steering wheel• Align slots in steering wheel with cancel cam protrusions of com-

bination switch.

Inspection after installationInspection: Noise from steering wheel

• Lightly turn the steering wheel left and right and check for noiseand other abnormalities.

• If any abnormality is found, disassemble the steering wheel, re-move the cause and reinstall.

37-22

Disassembly sequence

Assembly sequenceFollow the disassembly sequence in reverse.

1 Lock lever2 Nut3 Washer and stopper set4 Self-locking nut5 Return spring6 Bushing

7 Snap ring8 Steering column9 Stopper

10 Bearing spacer11 Stopper12 Snap ring

13 Grease nipple14 Steering joint15 Steering shaft bracket

: Non-reusable parts

STEERING COLUMN

37

37-23



Installation procedureInstallation: Steering joint

• When the steering joint has been separated at the splined por-tion, reconnect it so that the yokes of the upper and lower jointswill face in the same direction (arrows A).

Installation: Lock lever• Install the lock lever so that its operating range conforms to the

angle indicated in the illustration.


Bolt (lock lever mounting)9 to 14 {6.6 to 10, 0.9 to 1.4} –

Self-locking nut (steering column mounting)

Nut (steering column mounting) 29 ± 2 {21 ± 1.5, 3 ± 0.2} –

Grease nipple 3 to 5 {2.2 to 3.7, 0.3 to 0.5} –


Sliding surface of steering shaft bracket with steering col-umn Wheel bearing grease

[NLGI No. 2 (Li soap)] As requiredGrease through grease nipple

37-24

Removal sequence1 Drag link (See later section.)2 Feed pipe3 Return pipe

4 Power steering booster (See later section.)5 Gear box bracket

POWER STEERING BOOSTER AND DRAG LINK

37

37-25

CAUTION• When removing the drag link, use care not to deform or damage the dust cover.• Do not attempt to disassemble the drag link because it is of a unit construction.

Installation sequenceFollow the removal sequence in reverse.




Nut (drag link mounting)FK 190 ± 47.5 {140 ± 35, 19.4 ± 4.85}

–FM 353 ± 88 {260 ± 65, 36.0 ± 9.0}

Bolt or nut (power steering booster mounting)FK 150 to 200

{110 to 145, 15.0 to 20.0} –

FM 235 to 305 {175 to 225, 24 to 31} Wet

Bolt or nut (gear box bracket mounting)FK 240 to 290 {175 to 215, 24 to 29}

WetFM 345 to 415 {255 to 305, 35 to 42}


Lip area of drag link ball joint dust cover Molybdenum disulfide grease[NLGI No. 2 (Li soap)] As required

Bolt or nut thread Chassis grease[NLGI No. 1 (Li soap)] As required

37-26

Drag LinkDisassembly sequence

1 Clip <FK61>2 Dust cover3 Drag link


CAUTION• Do not attempt to disassemble the

drag link because it is of a unit con-struction.

• Do not remove the dust cover unless itis in an abnormal condition.

Assembly sequenceFollow the disassembly sequence in re-verse.




3 Drag link ball joint

Play

Under load of ±2000 N {±450 lbs, ±204 kgf}<FK61>

0 to 0.2 {0 to 0.0079} –

ReplaceUnder load of 430 N {97 lbs, 44 kgf}<FK62, FK65>

– 0.7{0.028}Under load of 500 N {110 lbs,

51 kgf}<FM>

Turning torque

FK610.5 to 8 N·m

{0.4 to 5.9 ft.lbs, 0.05 to 0.82 kgf·m}

– ReplaceExcept FK61

0.5 to 12 N·m {0.4 to 8.9 ft.lbs,

0.05 to 1.2 kgf·m}


Lip area of dust cover

Molybdenum disulfide grease[NLGI No. 2 (Li soap)]

As required

Inside of dust cover

FK61 11g {0.39 oz}

FK62, FK65 13 to 14g {0.46 to 0.49 oz}

FM 19 to 20g {0.67 to 0.71 oz}


37

37-27

Special tools (Unit: mm {in.})

Removal procedureRemoval: Clip

CAUTION• When removing the clip, take care not to deform or damage

the clip and dust cover.• Do not reuse the removed clip if it is deformed.


<FK61>MH061831 Installation of clip

Dust cover installer

<FK62, FK65>MH062804

<FM>MH061827

Installation of dust cover

End holder

<FK62, FK65>MH061830

<FM>MH061829

Clip guide

A B

φ53{2.09}

φ56{2.20}

A B C

FK62, FK65 φ65 {2.56}

φ56 {2.20}

100 {3.94}

FM φ65 {2.56}

φ51 {2.01}

100 {3.94}

A B C D

FK62, FK65 φ60 {2.36}

φ50.5 {1.99} φ35

{1.38}25

{0.98}FM65 φ64

{2.52}φ55.7 {2.19}

37-28

Inspection procedureInspection: Drag link

(1) Play<FK61>• Fix the drag link with a vise.

CAUTION• Take care not to deform or damage the dust cover when fix-

ing it with a vise.

• The position of the ball joint with applying no load is adjusted tostandard position.

• Measure each play of the ball joint with applying the specifiedpush and pull load from the standard position.

• Total each play and if the total deviates from standard value, re-place the tie rod end.

<Except FK61>• Fix the drag link with a vise.

CAUTION• Take care not to deform or damage the dust cover when fix-

ing it with a vise.

• If measured value deviates from the standard value with apply-ing the specified load (push) to the ball joint, replace the draglink.

(2) Rotation torque• Install the drag link mounting nut on the drag link.• Install the socket, adapter and torque wrench to measure the ro-

tation torque.• If the measured value deviates from the standard value, replace

the drag link.(3) Dust cover• Check that there are no wear, cracks or damage. There abnor-

malities can cause water to enter the ball joint, resulting in pre-mature wear.

• If wear, crack, or damage is present, inspect traces of water en-try and occurrence of rust in the ball joint. If any abnormality isfound, replace the drag link. If no abnormality is found, replacethe dust cover and reapply grease.


37

37-29

Installation procedureInstallation: Dust cover <Except FK61>

• Fill inside A with grease and apply grease to lip B of the dustcover.

• Pinch the dust cover with and and install reinforcedcollar C using a vise so that it is in close contact with the draglink.

Installation: Clip• Set the ball stud so that it is vertical.• Put on the drag link.• Install the clip in the dust cover groove.

CAUTION• Take care not to allow the tip of to be caught in the

dust cover.• Install the clip carefully so as not to damage the dust cover

with the tip of the clip.

37-30

Power Steering Booster<FK>


37

37-31

<FM>

37-32


CAUTION• Do not remove the parts marked with unless defects are evident.• Prepare a receiver when disassembling the parts that contain steel balls.

Assembly sequenceFollow the disassembly sequence in reverse except for the following.3→11→2

Repair kit: Power steering booster kit

Service standards (Unit: mm {in.})Location Maintenance item Standard value Limit Remedy

– Backlash between sector shaft and piston (measure at tip of pitman arm)

FK61 0.05 to 0.25 {0.0020 to 0.0098}

0.5 {0.020}AdjustFK62, FK65 0.05 to 0.25

{0.0020 to 0.0098}

FM 0.10 to 0.50{0.0039 to 0.020} –

9, 10 Looseness in adjusting screw and sector shaft 0.01 to 0.10{0.00039 to 0.0039} 0.2 {0.0079} Replace

10 Sector shaft out-side diameter

Adjusting screw side

FK61 φ39.975 {1.573} φ39.875 {1.569}

Replace

FK62, FK65 φ47.975 {1.89} φ47.875 {1.88}

FM φ47.975 {1.89} φ47.875 {1.88}

Pitman arm side

FK61 φ44.975 {1.77} φ44.875 {1.766}

FK62, FK65 φ47.975 {1.89} φ47.875 {1.88}

FM φ57.975 {2.282} φ57.875 {2.278}

17, 34 Looseness in piston and stub shaft and worm shaft in radial direction – 0.5 {0.020} Replace

17, 41 Piston outside diameter-to-body inside diameter clear-ance 0.11 {0.0043} 0.16

{0.0063} Replace

1 Pitman arm2 Dust cover3 Needle bearing4 Y-packing5 Backup ring6 O-ring7 Side cover8 Retainer9 Adjusting screw

10 Sector shaft11 Dust cover12 Ball tube clip13 Ball tube14 Steel ball15 Seal ring

16 O-ring17 Piston18 Ball bearing19 Oil seal20 Adjusting plug21 Wave washer 22 O-ring23 Seal ring24 O-ring25 O-ring26 Connector27 Plug28 Valve housing29 Side race30 Steel ball

31 Bearing cage32 Seal ring33 Rotor34 Stub shaft and worm shaft35 O-ring36 Oil seal37 Needle bearing38 Y-packing39 Backup ring40 Stud bolt <FK>41 Body



37

37-33




Lock nut (pitman arm mounting)

FK61 245 to 295 {180 to 215, 25 to 30}

–FK62, FK65 315 to 365 {230 to 270, 32 to 37}

FM 392 to 442 {290 to 325, 40 to 45}

Bolt (sector shaft mounting)FK61, FM 73.6 to 83.4 {54 to 62, 7.5 to 8.5}

–FK62, FK65 49.1 to 53.9 {36 to 40, 5 to 5.5}

Nut (adjusting screw tightening)FK61 63.7 to 73.5 {47 to 54, 6.5 to 7.5}

–Except FK61 117.7 to 127.5 {87 to 94, 12 to 13}

Plug (body, valve housing) 8.9 to 12.7 {6.5 to 9.4, 0.9 to 1.3} Sealant

Bolt (valve housing tightening)FK 98.1 to 107.9 {72 to 80, 10 to 11}

–FM 117.7 to 127.5 {87 to 94, 12 to 13}

Screw (ball tube clip mounting) 4.41 to 5.39 {3.3 to 4.0, 0.4 to 0.5} –

Adjusting plugFK61 177 to 195 {130 to 145, 18 to 20}

–Except FK61 226 to 245 {165 to 180, 23 to 25}

ConnectorFK61, FM 66.7 ± 12.8 {49 ± 9.4, 6.8 ± 1.3}

–FK62, FK65 108 to 127 {80 to 94, 11 to 13}

Stud bolt mounting FK62, FK65 25 to 69 {18 to 51, 2.5 to 7.0} –


Mating surfaces of nut and side coverHermeseal 101Y or

ThreeBond 1102 As requiredAdjusting screw thread

Outer surfaces of adjusting plug

Inner surfaces of backup ring

Multipurpose grease [NLGI No. 2 (Li soap)] As required

Fill in inner surfaces of Y-packing

Fill in inner surfaces of retainer

Fill in mating surfaces with sector shaft of adjusting screw

Fill inside ball tube

Fill in inner surfaces of oil seal

Wind around plug thread Seal tape As required

37-34

Special tools (Unit: mm {in.})Mark Tool name and shape Part No. Application

Pitman arm pullerA: BodyB: Bolt

<FK>MH061687*910-00183

<FM>MC064114*910-00184

Removal of pitman arm

Insert tool assembly MC811971*910-11001

Formation of backup ring and installa-tion of oil seal

Insert tool<FK61>

*910-21717

<Except FK61>MC811974*910-21715

Formation of backup ring (side cover side)

MC811948*910-21200 Removal of O-ring and seal ring

<FK61>MH063815*910-22813

<Except FK61>MC811955*910-22811

For turning of retainer

C D

FK 59 {2.32} φ92 {3.62}

FM 59 {2.32} φ100 {3.94}

A B C D

FK φ40 {1.57}

φ20{0.79}

52{2.05} φ33

{1.30}FM φ48

{1.89}φ25

{0.98}53.5

{2.11}

Needle

A B

120 {4.72}

φ3 {0.12}

Bar

A B

FK61 φ12.5 {0.49}

40 {1.57}

Except FK61

φ16.5 {0.65}

57 {2.24}


37

37-35


Squeeze tool <FK61>MH063816*910-21803

<Except FK61>MC811950*910-21801

For caulking of retainer

Insert tool<FK>

MC813516*910-21718

<FM>MC064115*910-21731

For forming seal ring of piston

<FK61>MH062883*910-10745

<Except FK61>MC811970*910-10743

Removal and installation of adjusting plug

MC811969*910-10671A:*910-23581B:*910-23194

Fixture of valve housing

A B C D E F

FK615

{0.20}8

{0.31}18

{0.71}φ30

{1.18}

4 {0.16} 160

{6.30}Except FK61

6 {0.24}

A B C

FK φ98 {3.86}

50 {1.97}

φ90.05 {3.55}

FM φ110 {4.33}

37 {1.46}

φ103 {4.06}

Wrench assembly

A B

FK61 φ52 {2.05} –

Except FK61

φ70 {2.76}

φ62 {2.44}

Attachment assemblyA: AdapterB: Bolt (pin)

C

φ147 {5.79}

37-36


Press-fit tool <FK61>MH062884*910-20405

<Except FK61>MC811972*910-20404

Installation of oil seal

Tool assembly MC811968*910-10611

Assembly of side race, steel balls and bearing cage

Guide assembly<FK61>

*910-23034

<Except FK61>MC090148*910-23033

Assembly of side race, steel ball and bearing cage

Insert tool<FK61>

MK590131*910-22777

<Except FK61>MC811975*910-22772

Formation of rotor seal ring

A B C D

FK61 φ54 {2.13}

φ46.8 {1.84}

φ36.26 {1.43}

30 {1.18}

Except FK61

φ45 {1.77}

φ40 {1.57}

φ24.6 {0.97}

27.5 {1.08}

A B C D

FK61 φ84 {3.31}

φ64.5 {2.54}

φ78 {3.07}

28 {1.10}

Except FK61

φ93.5 {3.68}

φ77.5 {3.05}

φ88 {3.46}

30 {1.18}

A B C

FK61 30 {1.18}

φ38.6 {1.52}

φ45 {1.77}

Except FK61

45 {1.77}

φ47.4 {1.87}

φ48 {1.89}


37

37-37

*: Unisia JKC Steering System Part No.


Insert tool <FK61>

*910-22773

<Except FK61>MC811975*910-22772

Formation of rotor seal ring of valve housing seal ring

Insert tool <FK61>MH062880*910-21716

<FK62, FK65>MC811974*910-21715

<FM>MC811973*910-21704

Formation of backup ring (body side)

A B C

FK6145

{1.77}

φ43.4 {1.71}

φ44 {1.73}

Except FK61

φ47.4 {1.87}

φ48 {1.89}

A B C D

FK61 φ45 {1.77}

φ20 {0.79}

45 {1.77}

φ33 {1.30}FK62, FK65 φ48

{1.89} φ25 {0.98}

53.5 {2.11}

FM φ58 {2.28}

37-38

Work before removalPreparatory work: Setting of pitman arm at neutral position

• Move the pitman arm and set the V-groove slit of the sector shaftat the center of the body to place gear engagement in neutralposition.

Removal procedureRemoval: Pitman arm

Removal: Sector shaft and side cover• Make sure that the piston is at the neutral position (the V-groove

slit of the end face of the sector shaft is in the center of thebody).

• Tap the end face of the sector shaft to remove the sector shaftand side cover.

Removal: Side cover• Remove the side cover by tightening the adjusting screw.


37

37-39

Removal: Retainer• Raise the caulked areas (two locations) of the retainer with a

chisel.

CAUTION• When pinching the sector shaft with a vise, be sure to apply

cloth to it to prevent damage.

Removal: Piston screw and valve housing• Before removing the piston and valve housing, return the adjust-

ing valve by approximately 180° using to loosen.

CAUTION• Only loosen the adjusting plug because removal of it may

cause the bearing in the valve housing to jump out.

• Remove the piston and valve housing from the body.

CAUTION• Take care not to allow the ball of the piston and valve hous-

ing to jump out.• Take care not to damage the inside of the body and the pis-

ton.

Removal: Piston• Hold the worm shaft and valve housing with the piston facing

downward, and turn the stub shaft and worm shaft to remove thepiston.

CAUTION• Steel balls assembled into the race of the piston and stub

shaft and worm shaft fall into the piston. Take care not totumble the piston.

37-40

Removal: Ball tube and steel ball• After removing the steel balls from the piston, remove the ball

tube clip and pinch the ball tube with fingers and lightly move itto remove from the piston.

CAUTION• Take care not to lose steel balls (30 pieces <FK> 32 pieces

<FM>).

Removal: Stub shaft and worm shaft• Press out the piston assembled side of the stub shaft and worm

shaft to remove from the valve housing.

CAUTION• The side race, steel balls and bearing cage come apart. Pre-

pare a receiver not to lose them.

Inspection procedureInspection: Looseness in piston and stub shaft and wormshaft

• Pull the worm shaft and valve housing to the dimension C as il-lustrated.

• Measure looseness B of the worm shaft and valve housing in theradial direction when a force of 49 N {11 lbs, 5 kgf} is applied toillustrated area A.

• If the measured value exceeds the limit, replace the defectivepart(s).

C (mm {in.})

FK 30.45 {1.20}

FM 42.8 {1.69}


37

37-41

Installation procedureInstallation: Backup ring and Y-packing

• Fill the Y-packing groove with grease and install it in the illustrat-ed direction.

• The backup ring can be easily installed in the illustrated shape.After installation, form it with and .

Installation: Oil seal• Install the oil seal on the body in the illustrated direction.

Installation: Seal ring• Install the seal ring on the rotor.• Form the seal ring with or .

37-42

Installation: Rotor• Install the notch of the rotor so that it is in alignment with the lo-

cating pin of the stub shaft and worm shaft.

Installation: Side race, steel ball and bearing cage• Assemble onto and install the stub shaft and worm

shaft in the illustrated direction.• Install the bearing cage and steel balls onto the stub shaft and

worm shaft.

• Hold by hand and slide downward to set the steelballs in place.

• Install the side race on the steel balls and bearing cage.


37

37-43

Installation: Seal ring and O-ring• Install the seal ring and O-ring on the valve housing.• Form the seal ring with .

Installation: Oil seal• Install the oil seal on the adjusting plug in the illustrated direc-

tion.

Installation: Stub shaft and worm shaft• Install the valve housing on the stub shaft and worm shaft and

secure it with adjusting plugs.

CAUTION• Take care not to damage the seal ring with the ball race of

the stub shaft and worm shaft.

• Secure the valve housing to a vise using .• Tighten the adjusting plug to the specified torque with , and

then loosen it by approximately 180°.

37-44

Installation: Seal ring and O-ring• Install the seal ring and O-ring on the outer surface groove of the

piston and form the seal ring with .

Installation: Ball tube• Fill the inside of the ball tube with grease, place 10 to 11 steel

balls, and lay another ball tube on top of the ball tube.• Place the piston on a flat bench and align the assembled worm

shaft and valve housing with the ball race position of the piston.While turning the stub shaft and worm shaft, drop steel ballsfrom the ball tube hole.

CAUTION• Take care that steel balls may fall off the ball race if the

worm shaft and valve housing is pulled out to the end faceposition.

Installation: Ball screw and valve housing• Face the gear of the ball screw and valve housing in the illustrat-

ed direction so that it can be engaged with the sector shaft.• Install the gear on the body while lightly holding down the gear

by hand to prevent it from turning. Align the ball screw and valvehousing with the oil passage holes of the body to install.

CAUTION• Take care not to damage the piston seal ring and the inside

of the body.


37

37-45

Installation: Retainer• Fill the adjusting screw mounting hole of the sector shaft with

grease.• Install the adjusting screw on the sector shaft.• Install the retainer on the sector shaft using .• After tightening, return the retainer by 180° once. Then, retighten

it to the torque of 39 N·m {29 ft.lbs, 4 kgf·m} and return it by 20°.• Make sure that the adjusting screw turns smoothly.

• Caulk caulked locations (two) of the retainer using .

Installation: Backup ring and Y-packing• Install the Y-packing on the side cover in the illustrated direction.• After installing the backup ring, fill the Y-packing groove with

grease.

• After installing the needle bearing, form the bend of the backupring using and .

37-46

POWER STEERING BOOSTER AND DRAG LINKInstallation: Sector shaft

• Set the V-groove slit of the sector shaft of the sector shaft andside cover at the center of the body, and install the sector shaftso that the gear of the piston is engaged with the gear of thesector shaft at their respective center.

CAUTION• Tape the Y-packing to install to prevent it from being dam-

aged by the sector shaft thread.

Tightening: Adjusting plug• After tightening the side cover mounting bolts to the specified

torque, retighten the adjusting plugs to the specified torque us-ing .

Installation: Pitman arm• Set V-groove slit A of the sector shaft at the center of the body,

and align V-groove slit B of the pitman arm or missing tooth posi-tion C of serration with slit A.

CAUTION• Make sure that the piston operates smoothly by letting the

piston make a full stroke using the pitman arm.

37

37-47

Adjustment after installationAdjustment: Backlash between sector shaft and piston

• Measure runout of the tip of the pitman arm with a dial gaugewith gear engagement placed in neutral position. Adjust usingthe adjusting screw so that the measurement is within the stan-dard value.

• After adjusting backlash, apply sealant to the adjusting screwthreads. Tighten the nut to the specified torque while securingthe adjusting screw with a screwdriver to prevent it from turning.

Measured load: ±15 N {3.4 lbs, 1.5 kgf} <FK> ±20 N {4.5 lbs, 2.0 kgf} <FM>

37-48


CAUTION• The flow control valve and body are of a unit construction.• Do not remove the plug unless it is in an abnormal condition.• See Gr11 for removal and installation of the power steering oil pump.


Repair kit: Seal repair kit, cartridge assembly kit

1 Oil hose (intake side)2 Oil hose (discharge side)3 Elbow4 O-ring5 Suction connector6 O-ring7 Plug8 O-ring9 Cover

10 O-ring11 Cartridge assembly12 Cam ring13 Vane14 Rotor15 O-ring16 Side plate17 O-ring18 O-ring

19 O-ring20 Connector21 Flow control valve22 Flow control spring23 Body


POWER STEERING OIL PUMP <FK>

37

37-49




Inspection procedureInspection: Flow control valve

• Plug port A of the flow control valve by a finger.• Apply air pressure (390 to 490 kPa {57 to 71 psi, 4 to 5 kgf/cm2})

to port B.• Check for any air leakage from port C.• If there is any abnormality, replace the power steering oil pump.

Installation procedureInstallation: Cam ring

• Install the cam ring on the body in the illustrated direction.


9 Stepped wear of sliding area of cover rotor and vane – 0.03 {0.0012} Replace

13, 14 Clearance between vane and rotor 0.01 {0.00039} 0.06 {0.0024} Replace

16 Stepped wear of sliding area of side plate rotor and vane – 0.03

{0.0012} Replace

21, 23 Clearance between flow control valve and body 0.01 to 0.02 {0.00039 to 0.00079}

0.03 {0.0012} Replace

22 Free length of flow control spring 36.5 {1.44} 33.5 {1.32} Replace


Elbow 68 {50, 6.9} –

Bolt (suction connector mounting) 7.8 to 11.8 {5.8 to 8.7, 0.8 to 1.2} –

Plug 15 to 20 {11 to 15, 1.5 to 2.0} –

Bolt (cover mounting) 22 to 26 {16 to 19, 2.2 to 2.7} –

Connector 49 to 69 {36 to 51, 5.0 to 7.0} –


Mating surfaces of connector and O-ringAutomatic transmission fluid

(DEXRON II or DEXRON III type) As requiredMating surfaces of elbow and O-ring

O-ring

37-50

POWER STEERING OIL PUMP <FK>Installation: Vane

• Install the vane on the rotor with its rounded area facing out-ward.

Installation: Elbow• Make sure that the nut and washer of the elbow and O-ring are

correctly positioned.• Clean the O-ring mount completely and apply power steering oil

to it. When assembling the O-ring, apply automatic transmissionfluid to it to prevent damage.

• Screw in the power steering oil pump by hand until the washercontacts the connector mounting surface. From that position,align the power steering oil pump with the upward angle of 20°from the horizontal direction of the body of the power steering oilpump in the loosening direction.

CAUTION• When returning the power steering oil pump to the speci-

fied position, do not turn it by more than 270°.

37

37-51

Installation: Oil hose (discharge side)• When installing the oil hose on the discharge side, provide suffi-

cient clearance (approximately 50 mm {2.0 in.} or more) to theexhaust insulator.

• Hold down the elbow with a spanner to prevent displacement ofthe elbow position and tighten the nut to the specified torque.

37-52


CAUTION• Do not attempt to disassemble the flow control valve because it is of a unit construction.• Do not remove the ball bearing and the oil seal unless necessary.• See Gr11 for removal and installation of the power steering oil pump.


Repair kit: Seal kit, cartridge assembly kit

1 Oil hose (suction side)2 Oil hose (discharge side)3 Elbow4 O-ring5 Hose connector6 O-ring7 Connector8 O-ring9 Flow control valve

10 Flow control spring11 Rear body

12 Pressure plate13 Cartridge assembly14 Cam15 Vane16 Rotor17 Side plate18 Straight pin19 O-ring20 O-ring21 Lock washer22 Oil pump gear

23 Key24 Retaining ring25 Ball bearing26 Drive shaft27 Retaining ring28 Oil seal29 Front body


POWER STEERING OIL PUMP <FM>

37

37-53




Special tools

* Unisia JKC Steering System Part No.

Removal procedureRemoval: Cartridge assembly

• Put mating marks on the outer surfaces of the pressure plate,cartridge assembly and side plate.

• Remove the screw, and then, remove the pressure plate, car-tridge assembly, side plate and straight pin as a set from thefront body.


9, 11 Flow control valve-to-front body clearance – 0.03 {0.0012} Replace

12, 17 Stepped wear of sliding area of pressure plate and side plate with rotor and vane – 0.01

{0.00039} Replace


Bolt (hose connector mounting) 17.7 to 24.5 {13 to 18, 1.8 to 2.5} –

Connector49.0 to 58.8 {36 to 43, 5 to 6} –

Bolt (rear body mounting)

Screw 5.9 to 8.8 {4.4 to 6.5, 0.6 to 0.9} –

Nut (oil pump, gear mounting) 29.4 to 39.2 {22 to 29, 3 to 4} –

Elbow 68 {50, 6.9} –


Mating surfaces of connector and O-ringAutomatic transmission fluid

(DEXRON II or DEXRON III type) As requiredMating surfaces of elbow and O-ring

O-ring


Pliers *910-22570 Removal and installation of retaining ring

Press-fit tool MK590134*910-22972 Removal and installation of bearing

Stick MK590137*910-21632 Removal of oil seal

Press-fit tool MK590135*910-22974 Installation of oil seal

37-54

Removal: Retaining ring

Removal: Ball bearing• Remove the ball bearing toward the drive side (gear side) of the

drive shaft.

Removal: Oil seal

Installation procedureInstallation: Oil seal

• Install the oil seal on the front body in the illustrated direction.

Installation: Ball bearing• To install the ball bearing, follow the removal procedure in re-

verse. (See “ Removal: Ball bearing”.)


37

37-55

Installation: Drive shaft• When installing the drive shaft into the front body, if it is not in-

serted into the normal position by hand, lightly tap the shaft witha plastic hammer to install.

Installation: Lock washer• After tightening the nut, bend one location on the circumference

of the lock washer.

Installation: Retaining ring• To install the retaining ring, follow the removal procedure. (See

“ Removal: Retaining ring”.)

Installation: Vane• Install the vane on the rotor with its R area facing outward, and

make sure that the vane moves smoothly.• If the vane is defective, replace the cartridge assembly.

37-56

Installation: Cartridge assembly• Install the straight pin on the front body.• Install the side plate, cartridge assembly and pressure plate in

alignment with mating marks put at the time of disassembly, andtighten screws to the specified torque.

CAUTION• Do not mistake pin holes of each part when installing.

Installation: Elbow• Make sure that the nut and washer of the elbow and O-ring are

correctly positioned.• Clean the O-ring mount completely and apply power steering oil

to it. When assembling the O-ring, apply automatic transmissionfluid to it to prevent damage.

• Screw the elbow in the power steering oil pump by hand until thewasher contacts the connector mounting surface. From that po-sition, align the elbow with the upward angle of 20° from the hor-izontal direction of the body of the power steering oil pump in theloosening direction.

CAUTION• When returning the elbow to the specified position, do not

turn it by more than 270°.


37

37-57

Installation: Oil hose (discharge side)• When installing the oil hose on the discharge side, provide suffi-

cient clearance (approximately 50 mm {2.0 in.} or more) to theexhaust insulator.

• Hold down the elbow with a spanner to prevent displacement ofthe elbow position and tighten the nut to the specified torque.

37-58

Disassembly sequence1 Hose2 Hose3 Cap4 Strainer5 Filter cap6 Packing7 Spring8 Filter9 Tank body

Assembly sequenceFollow the disassembly sequence in re-verse.

POWER STEERING OIL TANK

Documents

Group 37 Steering - JustAnswer · PDF fileFaulty power steering mechanism ... Difference excessive in degree of wear ... Power steering system fluid pressure (with hands off