STEERING SYSTEM

DESCRIPTION

SEQUENCE
1 From hydraulic tank 7 Power steering control valve
2 Hydraulic pump 8 Power cylinder assembly
3 Flow divider valve 9 Bellcrank for rear axle
4 Hydraulic control valve 10 To hydraulic tank
5 Main relief valve 11 Drag link assembly
6 Relief valve for flow divider valve 12 Socket end assembly

This steering is a hydrostatic power steering with a The steering control valve features a reaction chamber
semi-integral (follow-up mechanical) linkage which which senses steering load to permit the operator to
insures steering in the event of power failure. maintain full feel at all times.
The steering pressure is regulated by the relief valve
The flow divider provides a priority flow to the steering built in the flow divider.
system for smooth, responsive control under all operat- For the flow divider and relief valve, refer to HYDRAULIC
ing conditions, even at low engine speeds. SYSTEM.

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STEERING SYSTEM

REMOVAL AND INSTALLATION

Steering Gear and Power Cylinder
REMOVAL

SEQUENCE
1 Steering wheel, nut, grommet 6 Drag link assembly
[Tie-rod end assembly, nut, drag link]
2 Direction lever, clamp
7 Steering gear assembly
3 Console box cover, clamp, rubber
8 Socket end assembly
4 Floor plate, front cover [Tie-rod end assembly, nut, dust seal, grease fitting]
5 Nylon hose, pipe, O-ring, connector 9 Power cylinder assembly

START BY:

Disconnect the horn wires.

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 STEERING SYSTEM

SUGGESTIONS

1. Steering wheel removal

Use a special tool.

Special tool needed

Wheel puller 1022757

2. Power cylinder removal

Raise the rear end by jacking, and block it in raised con-
dition. Work under the truck to disconnect the power
cylinder and take it down by lowering it.

INSPECTION AFTER REMOVAL

Check the drag link for distortion, cracks and damaged

thread. Check the rod end for rattling. Check the dust
seal for damage.

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STEERING SYSTEM

INSTALLATION

Assembly dimensions and tightening torques

(1) Assembly dimensions A and B refer to exposed (2) Be sure to fill up each ball-and-socket joint with
threats measured from the end face of the nut. grease.

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 STEERING SYSTEM

DISASSEMBLY AND REASSEMBLY

Steering Gear
DISASSEMBLY

SEQUENCE
1 Pitman arm, nut, spring washer 8 Ring plate, needle roller bearing
2 Cap nut, gasket, nut 9 Steering column assembly
3 Side cover, O-ring, shim, adjusting screw 10 Ball screw assembly
4 Sector shaft [O-ring, needle roller bearing, oil seal,
column bushing]
5 End cover, O-ring
11 Gear box, snap ring, oil seal
6 Lock nut, ring plate, needle roller bearing
12 Needle roller bearing, O-ring
7 Valve assembly
[Ring plate, valve spool, reaction piston,
spring, pipe seat, valve housing]

START BY:

Before assembling the steering gear, measure the start-

ing torque of the worm with a torque wrench or spring
balancer.

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STEERING SYSTEM

WORKING RULES AND TIPS

The steering gear, complete with the control valve, is a
precision-machined component and, as such, must be
handled with greater care. Cleanliness is of utmost
importance: use clean tools and work in a clean place.

(1) Wash the disassembled parts, clean with a volatile

solvent such as trichlene or chlorobenzene, and dry
them with compressed air: this, however, does not
apply to rubber parts.
(2) Oil seals, O-rings and the like are rubber parts.
Never wash them with the solvent. Blow dirt off rub-
ber parts with compressed air, and keep them
immersed in a pool of hydraulic oil until they are used
in reassembly. A rubber part showing even slight
tear or wear must be replaced. Rubber parts are
expendable items, and should be renewed at inter-
vals of one year.
(3) Parts to be installed by pressing or forcing need spe-
cial treatment.
a) Oil seals
An oil seal removed must not be reused in
reassembly. After disassembling, examine the oil
seals in place (in the gear box and side cover)
and, if they are in sound condition, leave them
there. When installing a replacement oil seal, be
careful not to score or scratch its lip portion.
b) Needle roller bearings
These bearings are in the gear box and side
cover, all press-fitted in such a way that they are
not replaceable. If any of the needle roller bear-
ings is found in worn-down or otherwise defective
condition, replace the whole gear box and side
cover assembly.

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 STEERING SYSTEM

SUGGESTIONS

1. Pitman arm removal

Mark the pitman arm and sector shaft before disassembly.

Use a pitman arm puller or gear puller.
Special tool needed

2. Side cover removal

The cover comes off as the adjusting screw is turned

clockwise.

3. Sector shaft removal

Rotate the worm to bring the sector shaft to the position

show, and lightly drive on the serrated end of the shaft to
force it out of the box.

4. Loosening staked lock nut

Use a screwdriver.

5. Control valve disassembly

Remove the control valve from the gear box, and pull the
spool straight out, taking a firm grip on its head. Set the
valve body on the work table as shown, and take out the
internals by lifting them straight up.

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STEERING SYSTEM

6. Needle roller bearing removal

Use a special tool to remove the bearing from the steer-
ing column assembly as shown.
Special tool needed

7. Ball-screw assembly removal

Clamp the gear box in a vise, as shown, and pull out the
assembly in level direction. If any part of this assembly is
in bad condition to require replacement, replace the
whole assembly.

INSPECTION AFTER DISASSEMBLY

1. Control valve
Inspect the valve sleeve and spool for wear, rusting and
surface flaws such as scuffing, grooving, scratching, etc.,
and, as necessary, replace the two together.

2. Sector shaft
(1) Increase or decrease the shim thickness to
obtain a clearance of less than 0.1 mm (0.004 in.)
between adjusting screw and sector shaft. If the
head of the adjusting screw is worn down,
replace the screw.
(2) Replace the sector shaft if it is badly worn, dam-
aged or cracked.

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 STEERING SYSTEM

3. Ball-screw assembly
(1) If the recirculating-ball nut rotates sluggishly on the
screw, wash the assembly in a pool of washing
fluid, and test it again for smoothness of rotation.
(2) Check the steering shaft for distortion with a dial
gauge, as shown below; if the dial gauge reading
taken exceeds the limit, replace the shaft com-
plete with the ball nut.

A=Assembly standard
B=Repair or service limit
Unit: mm (in.)

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STEERING SYSTEM

REASSEMBLY

SEQUENCE
1 Gear box, needle roller bearing, oil seal, snap ring 5 End cover, O-ring
2 Ball screw assembly 6 Sector shaft, side cover, needle roller bearing, O-ring,
shims, adjusting screw, nut, cap nut
3 Steering column assembly
7 Pitman arm, spring washer, nut
[Column bushing, oil seal, needle roller bearing, O-ring]
4 Valve assembly
[Valve housing, pipe seat, spring, reaction piston,
valve spool, ring plate, needle roller bearing, lock nut]

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 STEERING SYSTEM

SUGGESTIONS

1. Gear box reassembly

Be sure to position the oil seal (for sector shaft) as

shown, pushing it into the bore until it barely clears the
snap ring groove; and secure the seal by snugly fitting
the snap ring.

2. Ball-screw assembly installation

Make sure that the largest-diameter part of the worm

shaft snugly fits into the needle roller bearing in place.

3. Column assembly reassembly

Both needle roller bearing and oil seal are meant to be

pressed into the rear cover.

4. Control valve reassembly

(1) Align P mark of the sleeve with the smaller

inside chamfer of the spool. Be sure to insert and
position the reaction piston and center spring
correctly.

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STEERING SYSTEM

(2) Install the needle roller bearing and plate. Then,

install the valve with P mark of the sleeve on the
front cover side.

(3) After installing the plate and needle roller bearing,

attach set plate A (special tool) on the control valve.
Tighten the lock nut to 4 to 5 kgfm (29 to 36 lbfft) [39
to 49 Nm] and stake it at two places. Then, make
sure that the starting torque of the shaft is less than
8.2 kgfcm (0.6 lbfft) [0.8 Nm]. After staking the lock
nut, make sure that the valve does not rattle.

Special tool needed

5. End cover installation

6. Sector shaft installation

Center the ball nut as seen in the opening, and insert the
sector shaft, positioning the two as in straight-ahead dri-
ving. Secure the side cover by tightening its securing
bolts to the specified torque.

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 STEERING SYSTEM

7. Pitman arm installation

The angular position of the pitman arm is fixed and iden-

tified by a match mark given to the sector shaft. Feed the
arm onto the serrated portion of the shaft and secure the
arm by tightening its nut to the specified torque.

INSPECTION AFTER REASSEMBLY

1. Backlash

Center the ball nut and, while holding the nut steady, try
to turn the pitman arm back and forth. Use a dial indica-
tor to measure the movement of the free end of pitman
arm, at a point exactly 195 mm (7.677 in.) from the axis
of sector shaft. The backlash, expressed in terms of this
movement, must be reduced to within the limit by reposi-
tioning the adjusting screw. The torque value for tighten-
ing the lock nut on this screw is specified.

2. Pitman arm swing angle

Rotate the steering wheel lock-to-lock and measure the

swing angle of the pitman arm.

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STEERING SYSTEM

3. Steering wheel starting torque (steering wheel side)

Hold the steering gear assembly in a vise with the pit-

man arm in vertical position and check the starting
torque in both directions.

4. Steering shaft rotation

Hold the steering gear assembly in a vise with the pit-

man arm in vertical position and make sure that the
steering shaft rotates smoothly in both directions.

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 STEERING SYSTEM

Power Cylinder
DISASSEMBLY

SEQUENCE
1 Guide assembly 3 Piston rod
[Dust seal, packing, bushing guide, O-ring]
4 Cylinder tube, tie rod end, nut, pin
2 Piston, self-locking nut, seal

SUGGESTIONS
Guide removal
(1) Loosen the staked spot of the cylinder tube, using
a pointed tool or, say, a screwdriver, with the
cylinder gripped in a vise at its port (elbow) sec-
tion.

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STEERING SYSTEM

(2) Put a special tool, hitching it to the notches provided

in the guide, and turn the guide counterclockwise to
loosen it until its threaded portion comes off.

Special tool needed

(3) Remove the piston rod complete with the guide

and piston from the cylinder tube.
(4) To remove the guide from the piston rod,
remove the piston and pull out the pin.

INSPECTION AFTER DISASSEMBLY

1. Cylinder tube
Check the cylinder tube for wear, scuffing, scratch marks
and rusting at its bore surface.
2. Piston rod
Check the piston rod for dents, scoring and wear, and
check for deflection.

3. Sealing parts

Replace the dust seals, packings and O-rings at the time

of disassembly or every 1 year.

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 STEERING SYSTEM

REASSEMBLY
To reassemble, follow the reverse of disassembly pro-
cedure, and proceed as follows:
1. Dust seal installation

Using a spatula-like tool, fit the dust seal to the guide.

2. Guide bushing installation

Using a special tool, install the guide bushing to the

piston rod.
Special tool needed

3. Piston installation

Put the piston on the piston rod, and tighten the self-lock-
ing nut to the specified torque.

4. Piston installation

Using a special tool, gently insert the piston rod into the
cylinder tube.
Special tool needed

5. Tightening guide bushing

Tighten the guide bushing to the specified torque.

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STEERING SYSTEM

6. Staking cylinder tube

Connect the steering hose to the power cylinder assem-

bly. Apply hydraulic pressure to the cylinder to make
sure that the cylinder is free from leakage. Then, stake
the tube at one place.

INSPECTION AND ADJUSTMENT

Steering Wheel Free Play
With the engine running at idle speed, measure the free
play at the wheel rim.

If the free play is off this range, correct it by referring to

TROUBLESHOOTING.

Steering Effort
1. Set the parking brake. Run the engine to warm up
the hydraulic oil (until the engine coolant temperature
gauge needle moves into the white zone).

2. Hook a spring balancer to the rim of steering wheel

and turn the wheel. Read the balancer indication
when the wheel begins to turn with the engine idling.
This effort should not exceed the standard value.

Relieving Pressure Adjustment

Refer to HYDRAULIC SYSTEM.

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