Power Steering: Models FA and FB
Power Steering: Models FA and FB
Power Steering: Models FA and FB
67-61E-13
CHAPTER 67
POWER STEERING
Models FA and FB
TROUBLESHOOTING ...............................................................67 - 2
DIAGNOSIS ...............................................................................67 - 4
67
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67-2 POWER STEERING Models FA and FB
TROUBLESHOOTING
SPECIAL TOOLS
Prior to starting of the power steering overhaul, it is necessary to have these special tools.
DIAGNOSIS
THOROUGHLY CLEAN ALL JOINTS OF THE 1. CHECKING FLUID LEVEL
STEERING GEAR, RESERVOIR, PUMP AND Check fluid level by means of the level gauge
LINES BEFORE INSPECTING THE POWER in the power steering reservoir. Replenish fluid
STEERING SYSTEM. if necessary. Inspect for any leaks and repair
NOTE: if necessary.
Any foreign matter (fluid, dust, grime) in NOTE:
fluid causes valves and seals to clog up, ● Use only power steering fluid.
thus lowering hydraulic pressure, causing ● Do not overfill the reservoir tank.
machine malfunction and shortening the ● Replace old fluid with new fluid after
pump service life. overhauling any gear or pump compo-
nents.
● Power steering fluid ............Refer to
RECOMMENDED LUBRICANT LIST.
POWER STEERING PUMP
6 7
4
8
3
2
9
1
10
11
12 SM67-343
15 14 6
13
6
1. Pump shaft 9. Rear body
2. Ball bearing 10. Vane
3. Front body 11. Rotor
4. Plug 12. Side plate
5. Spring 13. Knock pin
6. O-ring 14. Needle roller bearing
7. Relief valve 15. Oil seal
8. Flow control valve assembly
Fig. 1
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Models FA and FB POWER STEERING 67-5
FLUID RESERVOIR
7 4
SM67-398
Fig. 2
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67-6 POWER STEERING Models FA and FB
1. Fluid leakage from the power steering 1. Bleeding air in the system.
gear. If there is any air mixed in the fluid, elimi-
Inspect for fluid leakage from the worm nate it in the following manner.
shaft, end plug, sector shaft, side cover a. Block the rear wheels then jack up the
top cover and adjuster screw. front wheels and support them over a
stand.
NOTE: b. Pour pump fluid into the reservoir within
When replacing the worm shaft oil seal, MIN LEVEL of the dipstick.
replace the entire kit. c. Turn the steering wheel from lock to lock.
d. Start the engine and keep turning the
2. Fluid leakage from the pump and tank. steering wheel from lock to lock until all
Check for any fluid leakage from the air is eliminated from the fluid.
seals. Replace the entire seal kit if nec- e. Stop the engine and fill the reservoir
essary . within MAX LEVEL of the dipstick.
3. Fluid leakage from lines. f. Lower the front wheels.
Check for fluid leakage from line joints
(joining flare nuts or hoses) and hose end NOTE :
joints (nuts or line connections). ● The fluid reservoir must not be empty
If there is any leakage: while bleeding air in the system.
a. Tighten the nut or hose clamp. ● The fluid level must not change greater
b. Replace lines if any damage, cracks or than 5 mm (0.20 in.) after stopping the
corrosion on seal surfaces is found. engine. Otherwise, repeat the air bleed-
c. Replace hoses if any damage or cracks ing operation.
are found.
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Models FA and FB POWER STEERING 67-7
2. Hydraulic test
GAUGE
STOP
VALVE
RESERVOIR
TANK
Fig. 3
3. Final Inspection
a. Start the engine and turn the steering
wheel fully from right to left and make
sure that its movement is smooth.
NOTE:
When turning the steering wheel, support
the front tires on a turntable and idle the
engine. The steering force in this condition
should be less than 2 kg (4.4 Ib).
3
7
8
5 4
5
9
4
10 6
4
4
11
12
5
4
4
7
SM67-476
Fig. 1
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67-10 POWER STEERING Models FA and FB
DISASSEMBLY
Mount the gear unit in a vise.
1. REMOVE THE PITMAN ARM.
1. Remove the pitman arm mounting nut and lock
washer with a socket wrench.
NOTE: Width of socket wrench: 46 mm (1.81 in.)
2. Remove the pitman arm with a special tool.
Special tool: Pitman arm puller (09650 - 1260)
SM12-086
Fig. 2
2. REMOVE THE SIDE COVER SUB-ASSEMBLY.
1. Remove the seal lock nut.
NOTE: Fit a hexagonal wrench 6 mm (0.24 in.) on the
adjusting screw.
2. Remove the side cover sub-assembly mounting nut
and bolt.
SM67-460
Fig. 3
3. Tighten the adjusting screw with a hexagonal wrench
6 mm (0.24 in.) and remove the side cover.
SM67-475
Fig. 4
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Models FA and FB POWER STEERING 67-11
SM67-457 SM67-458
Fig. 5
3. REMOVE THE SECTOR SHAFT SUB-ASSEMBLY.
1. Position the sector shaft work at right angle to the
housing.
2. Tap the sector shaft sub-assembly lightly with a plas-
tic-faced hammer for removal.
NOTE: Be careful not to damaged the internal gear
housing.
SM67-474
Fig. 6
4. REMOVE THE POWER PISTON SUB-ASSEMBLY.
1. Remove the dust cover.
2. Remove the power piston sub-assembly mounting
bolt.
3. Hold the piston of the power piston sub-assembly
with one hand and turn the worm shaft unit the O-
ring at the cover is detached from the gear housing.
SM67-473 WARNING
Fig. 7 Keep the power piston sub-assembly horizontal. If
it is inclined, the piston may fall due to its own
weight.
SM67-468 SM67-469
Fig. 11
3. Install a new oil seal with a special tool.
NOTE: Apply lithium grease to the oil seal lip.
Special tool: Oil seal guide (09657 - 1290)
SM67-467
Fig. 12
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Models FA and FB POWER STEERING 67-13
SM67-469
Fig. 13
5. REPLACE THE SECTOR SHAFT OIL SEAL.
(Gear housing side)
1. Remove the O-ring and oil seal with a flat-bladed
screwdriver.
NOTE: Be careful not to damage the gear housing.
2. Install the new oil seal O-ring.
NOTE: ● Apply ATF to the oil seal lip and O-ring.
● Pay attention to the installation direction
SM67-466
of the oil seal.
Fig. 14
6. REPLACE THE SECTOR SHAFT OIL SEAL.
(Side cover side)
1. Remove the oil seal and bushing with a flat-bladed
screw driver.
NOTE: Be careful not to damage the side cover.
2. Install a new oil seal.
NOTE: ● Apply ATF to the installation direction of
the oil seal.
SM67-465
● Pay attention to the installation direction
Fig. 15
of the oil seal.
3. Install the new bushing.
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67-14 POWER STEERING Models FA and FB
SM67-531
Fig. 17
9. INSPECT THE SECTOR SHAFT SUB-ASSEMBLY.
1. Check the teeth for wear and damage.
2. Check the bearing rolling surface for wear and
damage.
3. Check the taper serration for damage.
4. Check the adjust bolt threads for damage.
SM67-532
Fig. 18
5. Check the staked ring screw for looseness.
NOTE: In checking for cracks in the sector shaft, use
color check instruments, etc.
SM67-533
Fig. 19
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Models FA and FB POWER STEERING 67-15
3
SM67-429A
Fig. 21
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67-16 POWER STEERING Models FA and FB
DUST COVER NOTE: Apply lithium grease inside the dust cover.
SM67-366
Fig. 23
4. Tap the oil seal into the top cover using the special
tool.
5. Fix the top cover and tighten the nuts to the speci-
fied torque.
Tightening torque: 750 - 1,050 kg·cm (55 - 76 lb·ft)
SM67-430
Fig. 24
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Models FA and FB POWER STEERING 67-17
6. Fix the side cover with nuts and bolts to the speci-
fied torque.
Tightening torque: 750 - 1,050 kg·cm (55 - 76 lb·ft)
SM67-431
Fig. 27
3. PRELOAD ADJUSTMENT
1. Adjust the frinction torque of the worm shaft with the
adjusting screw to within in the standard value.
Standard: 3.5 - 10 kg·cm (3.1 - 8.6 lb·in.)
2. Tighten the seal lock nuts to the specified torque.
Tightening torque: 1,000 kg·cm (72 lb·ft)
NOTE: Always use a new seal lock nut.
3. After tightening the seal lock nut, check the worm
SM67-461 preload again.
Fig. 28
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67-18 POWER STEERING Models FA and FB
SM67-459
Fig. 29
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Models FA and FB POWER STEERING 67-19
14 13
12
9
15
12
9
11
10
4 9
3
2
7 8
6
1 5
SM67-344
Fig. 1
1 page 1
67-20 POWER STEERING Models FA and FB
REMOVAL
BEFORE DISCONNECTING THE PUMP AND LINES, CLEAN
AWAY ANY FOREIGN MATTER.
1. DISCONNECT THE LOW PRESSURE HOSE AND HIGH
PRESSURE HOSE FROM THE PUMP.
SM67-434
Fig. 2
2. REMOVE THE TWO BOLTS AND TAKE OUT THE PUMP.
DISASSEMBLY
1. CLAMP THE GEAR IN THE VISE.
SM67-085
Fig. 4
5. REMOVE THE PUMP SHAFT.
1. Using snap ring pliers, remove the retainer ring.
WARNING
The retainer ring is spring steel and may pop out of
the groove. Wear safety glasses to protect your
eyes.
SM67-401
Fig. 5
2. Using a sliding hammer and adapter, remove the
pump shaft with bearing.
SM67-402
Fig. 6
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Models FA and FB POWER STEERING 67-21
SM67-403
Fig. 7
2. Remove the front body with knock pin.
3. Remove the O-ring.
SM67-404
Fig. 8
7. REMOVE THE ROTOR AND VANES.
SM67-405
Fig. 9
8. REMOVE THE SIDE PLATE.
1. Using a plastic hammer, tap the rear body, and re-
move the cam ring, side plate and spring.
SM67-407
Fig. 11
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67-22 POWER STEERING Models FA and FB
INSPECTION
1. INSPECT THE PUMP SHAFT.
1. Check the pump shaft for wear or damage.
2. Check that the pump shaft bearing rotates smoothly.
If the bearing is scratched or damaged, replace it.
SM67-408
Fig. 12
3. If necessary, replace pump shaft bearing.
a. Using snap ring pliers, remove the shaft spring ring.
WARNING
The retainer ring is spring steel and may pop out from
groove. Wear safety glasses to protect your eyes.
SM67-012 SM67-080
Fig. 14
2. INSPECT THE OlL SEAL.
Check the oil seal for wear or damage.
SM67-087
Fig. 15
3. REPLACE THE OIL SEAL, IF NECESSARY.
1. Remove the oil seal.
Using a screwdriver, remove the oil seal.
SM67-079
Fig. 16
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Models FA and FB POWER STEERING 67-23
SM67-093
Fig. 17
3. Using special tool and press, press in the oil seal.
SPECIAL
TOOL Special Tool: Press (09434 - 1110)
OIL
SEAL
SM67-053 SM67-089
Fig. 18
4. INSPECT THE NEEDLE ROLLER BEARING
Check the needle roller bearing rotates smoothly.
SM67-410
Fig. 20
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67-24 POWER STEERING Models FA and FB
SM67-083
Fig. 21
INSPECT THE FLOW CONTROL VALVE.
1. Check the flow control valve for wear or damage.
2. Apply power steering fluid to the valve and check
that it falls smoothly into the valve hole by its own
weight.
If a problem is detected, replace the flow control valve
assembly.
Power steering fluid:
SM67-103 Refer to RECOMMENDED LUBRICANTS LIST.
Fig. 22
ASSEMBLY
A
BEFORE ASSEMBLING, CLEAN ALL THE PARTS AND
LUBRICATE THEM WITH POWER STEERING FLUID.
Power steering fluid:
B
Refer to RECOMMENDED LUBRICANTS LIST.
NOTE: There are three different valves in diameter,
therefore be careful that the mark on both
valve and the pump body are always
SM67-563 SM67-094A matched.
IDENTIFICATION MARK
PUMP BODY (A) VALVE (B)
TWO LINE
0
ONE LINE
1
NO LINE
2
Fig. 23 SM67-553
SM67-411 SM67-412
Fig. 24
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Models FA and FB POWER STEERING 67-25
SM67-081A
Fig. 25
2. Using special tool or press, install the pump shaft
into the front body.
SM67-082A
Fig. 26
3. Retainer ring installing direction.
CHAMFER
SM67-70B
Fig. 27
4. Install the retainer ring with snap ring pliers.
WARNING
The retainer ring is spring steel and may pop out
from the groove. Wear safety glasses to protect your
eyes.
SM67-413
Fig. 28
3. INSTALL THE CAM RING.
DOT MARK 1. Install the knock pin into the front body.
2. Install the cam ring with the pin hole aligned with
knock pin.
FRONT
BODY
SM67-414 SM67-097
Fig. 30
2. Install the vane with the round end facing outward.
OUTSIDE
SM67-415 SM67-098
Fig. 31
5. INSTALL THE SIDE PLATE AND SPRING.
A q 1. Place the side plate on the cam ring with pin hole
A aligned with the knock pin.
w
2. Place the spring on the side plate hole.
SM67-416 SM67-417
Fig. 33
7. INSPECT PUMP SHAFT ROTATION CONDITION.
Check that the pump shaft rotates smoothly without
abnormal noise.
SM67-418
Fig. 34
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Models FA and FB POWER STEERING 67-27
SM67-104
Fig. 35
INSTALLATION
1. INSTALL THE PUMP.
1. Install the pump to the engine and tighten the bolts.
FLUID RESERVOIR
SM67-339
1. Cap
2. Oil strainer
3. Reservoir sub-assembly
Fig. 1
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Models FA and FB POWER STEERING 67-29
INSPECTION
BEFORE REMOVING THE RESERVOIR CAP, CLEAN AWAY
ANY FOREIGN MATTER FROM RESERVOIR.
INSPECT THE OIL STRAINER
If the oil stainer is damaged, replace it with a new one.
SM67-339C
Fig. 2
REPLACEMENT OF POWER STEERING FLIUD
1. BLOCK THE REAR TIRES AND JACK UP THE FRONT
OF VEHICLE THEN SUPPORT IT WITH STANDS.
SM67-421
Fig. 3
2. TURN THE STEERING WHEEL FROM LOCK TO LOCK
WHILE DRAINING FLUID.
3. AFTER DRAINING FLUID, INSTALL THE DRAIN PLUG
TO POWER STEERING GEAR BOX.
SM67-282B
Fig. 4
4. FILL THE RESERVOIR WITH POWER STEERING
FLUID.
SM67-420A
Fig. 5
5. TURN THE STEERING WHEEL FROM LOCK TO LOCK
SEVERAL TIMES AND CHECK THE FLUID LEVEL.
Check the fluid level and add power steering fluid if
necessary.
NOTE: Check that the fluid level is between MIN and
MAX.
SM67-422
Fig. 6
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67-30 POWER STEERING Models FA and FB
WARNING
When checking the fluid level of the power steer-
SM67-420A ing reservoir or adding fluid to the reservoir, be
Fig. 1 careful not to contaminate fluid by letting dirt fall
into the reservoir. Fluid contaminated with dirt can
result in a shorter life of the pump, and can result
in personal injury and/or property damage due to
improper operation of relief valve, central valve, etc.
SM67-394
Fig. 2
2. Check that the steering wheel turns smoothly
without any shocks or abnormal resistance, when it
is turned full range.
SM67-282B
Fig. 3
3. Measure the steering wheel turning force.
SM12-373A
Fig. 4
4. Check the steering wheel play.
WARNING
Excessive steering wheel play may adversely
affect vehicle handling. This can result in personal
injury and/or property damage.
SM67-284B
Fig. 5