MANUAL RACK AND PINION 3B-1

SECTION 3B

MANUAL RACK AND PINION

NOTE:
All steering gear fasteners are important attaching parts in that they could affect the performance
of vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
3B
use a replacement part of lesser quality or substitute design. Torque values must be used as speci-
fied during reassembly to assure proper retention of these parts.

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CONTENTS

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 1

DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 2
Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 2
Steering Wheel Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 2
Steering Rack Boot Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 2
Tie Rod End Boot Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 3
Steering Shaft Joint Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 3
Tie Rod End Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 3
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 3
Manual Rack and Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- 9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-13
REQUIRED SERVICE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-15
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-16

GENERAL DESCRIPTION
The rack and pinion steering system consists of two main components, the rack and the pinion. When the steering
wheel is turned, the motion is transmitted to the steering shaft, lower shaft and then to the pinion.
Since the pinion teeth mesh with teeth on rack, the motion is further transferred to the rack and changed to linear
motion. The force is then transmitted through the tie rods to the steering knuckles which turn wheels.
3B-2 MANUAL RACK AND PINION

DIAGNOSIS
DIAGNOSIS TABLE
Refer to Section 3.

STEERING WHEEL CHECK

Check steering wheel for play and rattle, holding vehicle in straight
forward condition on the ground.
Steering wheel play “a”: 0 – 30 mm (0 – 1.18 in)
If steering wheel play is not within specification, inspect as follows
and replace if found defective.

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Tie rod end ball stud for wear (ball stud should move when less
than 3.4 N·m (0.34 kg-m) torque is applied.)

Suspension control arm joint for wear

Steering shaft joint for wear

Steering pinion or rack gear for wear or breakage

Each part for looseness

STEERING RACK BOOT CHECK

Hoist vehicle.
Inspect each boot for tear. A torn boot allows entry of dust and wa-
ter which can cause wear to steering rack and pinion to produce
noise as well as rust to result in malfunction of steering system.
If even a small tear is noted, replace with new one.
Boots should be visually inspected for any damage and tear during
every periodical inspection at specified intervals and whenever ve-
hicle is hoisted for any other purpose.
 MANUAL RACK AND PINION 3B-3

TIE ROD END BOOT CHECK

Inspect each boot for tear. If even a small tear is noted, replace with
new one.

STEERING SHAFT JOINT CHECK

Check shaft joint for wear, breakage and other damage and re-
place if any defect exists.

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TIE ROD END CHECK

Inspect for play in ball joint.

Inspect for play in rack end ball joint.
In either case, if found defective, replace.

ON-VEHICLE SERVICE
NOTE:
According to necessity, apply works to right and left parts.

LUBRICATION
When inner parts of the steering gear case were disassembled,
they should be washed clean before reassembly. It is recom-
mended to use the grease as given at the right where grease ap-
plication is indicated in the text.

SUZUKI SUPER GREASE E (99000-25050) or Lithium

grease (applicable for –40
C to 130
C (–40
F to 266
F))
3B-4 MANUAL RACK AND PINION

1. Steering lower shaft 10. Rack damper screw: 21. Steering rack:
2. Steering lower shaft lower bolt Note the installing procedure, and the Apply SUZUKI SUPER GREASE E
3. Steering gear case oil seal: detail refer to page 3B-12. 99000-25050 to entire surface of rack.
Apply SUZUKI SUPER GREASE E 11. Packing 22. Tie-rod lock washer
99000-25050 to oil seal lip. 12. Cap 23. Steering tie-rod:
4. Pinion bearing plug: 13. Cotter pin Apply SUZUKI SUPER GREASE E
Fill SUZUKI SUPER GREASE E 14. Castle nut 99000-25050 to rack end ball joint.
99000-25050 to inside of pinion bearing plug. 15. Tie-rod end 24. Wire
5. O-ring 16. Steering pinion side mount 25. Boot:
6. Steering pinion: 17. Bracket (Pinion side) Apply SUZUKI SUPER GREASE E
Apply SUZUKI SUPER GREASE E 18. Bracket bolt 99000-25050 to contacting part of
99000-25050 to all around pinion teeth 19. Steering rack housing and gear case tie-rod and boot.
and mating surface of pinion bearing. 20. Steering rack side mount 26. Clamp
7. Pinion needle bearing: 27. Tie-rod end lock nut
Apply SUZUKI SUPER GREASE Ex 28. Bracket (rack side)
99000-25050 to rollers of pinion needle bearing. 29. Steering rack bushing:
8. Steering rack plunger: Apply SUZUKI SUPER GREASE
Apply SUZUKI SUPER GREASE E E 99000-25050 lightly to entire inner
99000-25050 to sliding part of plunger. surface of bushing.
9. Rack plunger spring 30. Snap ring

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: Tightening Torque

: Do not reuse
 MANUAL RACK AND PINION 3B-5

MANUAL RACK AND PINION ASSEMBLY

REMOVAL
1) Remove steering joint cover.
2) Loosen steering lower shaft upper bolt (1), but don’t remove.
3) Remove steering lower shaft lower bolt (2) and disconnect
steering lower shaft from steering pinion shaft.
4) Hoist vehicle and remove front wheels.

5) Remove cotter pins (1) and tie rod castle nuts (2) from both
knuckles (3).
6) Disconnect tie rod ends (4) from knuckle using special tool.
Special Tool
(A): 09913-65210

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< Right side >
7) Remove steering gear case mount bolts (1), and then remove
steering gear case mount brackets (2).

< Left side >

8) Remove exhaust pipe (1).

3B-6 MANUAL RACK AND PINION

9) Disconnect gear shift control shaft (1) and extension rod (2)
from transmission assembly (3).

10) Support engine with transmission jack (1) as shown.

11) Remove engine member rear bolts (2).
12) Lower engine, and then remove manual rack and pinion as-
sembly (3) as shown.

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DISASSEMBLY
1) For ease of adjustment after installation, make marking (1) on
tie rod end lock nut position of tie rod thread.
2) Loosen tie rod end lock nut (2) and remove tie rod end (3).

3) Remove boot wire (1) and clamp (2).

4) Remove boot (3) from tie rod.
 MANUAL RACK AND PINION 3B-7

5) Unbend bent part of tie rod lock washer (1) and remove tie rod
(2) from steering rack (3).

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6) Remove rack damper screw cap (1), rack damper screw (2),
rack plunger spring (3), and rack plunger (4).

7) Remove pinion bearing plug (1) using special tool.

Special Tool
(A): 09944-26011 (43 mm socket)

8) To remove pinion assembly (1) from rack housing (2), tap rack
housing (2) using plastic hammer (3) as shown.
3B-8 MANUAL RACK AND PINION

9) Remove rack (1) from gear case (2) as shown.

CAUTION:

Inside of steering rack bushing is coated with spe-
cial coating. As it is damageable, be very careful
not to cause damage to it when removing rack
from steering gear case.

Do not use a wire brush when cleaning.

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10) Pull out pinion needle bearing (1) from gear case using special
tools.
Special Tool
(A): 09921-20200
(B): 09930-30104

11) Remove snap ring (1).

12) Pull out rack bushing (2) from rack housing (3) using special
tool.
Special Tool
(A): 09944-48210

CAUTION:
When removing the rack bushing, be careful not to
pull out the bushing by holding the gear case in a
vise. Or the housing (pipe) may come off the gear
case.
For this work, be sure to use the specified special
tool.
 MANUAL RACK AND PINION 3B-9

13) Remove gear case oil seal (1) using special tool.
Special Tool
(A): 09913-50121
14) Remove gear case O-ring (2).

INSPECTION
Rack Plunger

Inspect rack plunger (1) for wear or damage.

Inspect rack plunger spring (2) for deterioration.
If found defective, replace.

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Steering Pinion

Inspect teeth surface of steering pinion (1) for wear or damage.

Inspect oil seal (2) for damage.

Inspect gear case O-ring (3) for damage.
If found defective, replace.

Steering Pinion Bearing

Check rotation condition of bearing and inspect for wear.
If found defective, replace.

Steering Rack
Inspect for deflection, teeth wear damage, rack surface wear or
damage.
Limit of rack deflection: 0.35 mm (0.014 in)
If deflection exceeds limit, replace rack.
3B-10 MANUAL RACK AND PINION

Steering Rack Bushing

Inspect rack bushing for wear or damage.
If found defective, replace.

REASSEMBLY
Install in reverse order of disassembly, noting the following points.

Install pinion bearing oil seal to pinion bearing plug (1) using spe-
cial tool.
Special Tool
(A): 09925-98210

Apply grease to oil seal lip.

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Grease: 99000-25050

Apply grease lightly to entire inner surface of bushing (1).

Grease: 99000-25050

Press-fit bushing as far into rack housing (2) as shown by using
special tool.
Special Tool
(A): 09925-98210

Distance “a”: 2.0 – 3.0 mm (0.08 – 0.12 in.)

Install snap ring (3).
 MANUAL RACK AND PINION 3B-11

Apply grease to rollers of pinion needle bearing (1).

Grease: 99000-25050

Press-fit pinion needle bearing (1) into gear case (2) using spe-
cial tool.
After press-fitting, make sure that bearing rollers are installed
properly.
Special Tool
(A): 09943-88211

Apply grease to entire teeth surface of steering rack (1) and its
periphery.
“A”: Grease 99000-25050

Slide steering rack (1) into steering gear case (2) in the direction
as shown.

CAUTION:

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Inside of steering rack bushing is coated with spe-
cial coating. As it is damageable, be very careful not
to cause damage to it when inserting rack into steer-
ing gear case.

Do not use a wire brush when cleaning.

Apply grease to all around pinion teeth (1), pinion bearing (2)
and gear case oil seal lip (3) as shown.
“A”: Grease 99000-25050

Fill inside (4) of pinion bearing plug (5) with grease.
“A”: Grease 99000-25050

Fit gear case O-ring (6) in groove of pinion bearing plug.

Install pinion assembly (1) and tighten pinion bearing plug (2) to
specified torque.
Special Tool (43 mm socket)
(A): 09944-26011
Tightening Torque
(a): 95 N·m (9.5 kg-m, 69.0 lb-ft)
3B-12 MANUAL RACK AND PINION

Apply grease lightly to sliding part of plunger (1) against rack.

“A”: Grease 99000-25050

Install rack plunger (1), rack plunger spring (2) and rack damper
screw (3) and adjust rotation torque of pinion as follows.
i) After tightening rack damper screw (3) to the tightest point,
turn it back by 05 – 905 and check for rotation torque of pinion.
If it is not as specified below, adjust so that it will be within
specified torque range.
Special Tool
(A): 09944-18211
Rotation torque of pinion
0.8 – 1.3 NVm (0.08 – 0.13 kg-m, 0.6 – 0.9 lb-ft)
Also, check if rack as a whole moves smoothly.
ii) After adjustment, put rack damper screw cap (4) as deeply
as possible.

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Install new tie rod lock washer (1) as shown, and then install tie
Upper
rod (2) to steering rack (3). Align straight part “A” of washer with
flat part “B” of steering rack.

Tighten tie rod to specified torque.
Tightening Torque
(a): 85 N·m (8.5 kg-m, 61.5 lb-ft)

Bend lock washer to tie rod side as shown.

 MANUAL RACK AND PINION 3B-13

Before installing boot to steering rack housing (1), make sure

that rack side mount (2) is positioned as shown.
Distance “a” 1.0 – 2.0 mm (0.04 – 0.08 in.)

Position boot (1) properly in grooves of gear case and tie rod,
and then clamp it with wire (2) and clip (3).
Wire should be new and should go around twice and be tight-
ened with its both ends twisted together. The twisted ends
should be bent in the circumferential direction. After this, check
to ensure that boot is free from twist and bent.
Apply grease to all around inner surface of hatched part.

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“A”: Grease 99000-25050

Install tie rod end lock nut and tie rod end to tie rod. Position lock
nut to marking (1) made in removal.
NOTE:
When tie rod was replaced, measure length “a” on removed
tie rod end and use it on new replacement tie rod end so as
to position lock nut properly.

INSTALLATION
< Right side > < Left side >
For installation, reverse removal procedure, note the following
instructions.

Tighten rack and pinion assembly mounting bolts (1) to specified
torque.
Tightening Torque
(a): 25 N·m (2.5 kg-m, 18.0 lb-ft)

Hoist engine with transmission jack (1), and then tighten engine
member rear bolts (2) to specified torque.
Tightening Torque
(a): 40 N.m (4.0 kg-m, 30.0 lb-ft)
3B-14 MANUAL RACK AND PINION

Connect extension rod (1) and gear shift control shaft (2) to
transmission assembly.
Tightening Torque
(a): 6 N.m (0.6 kg-m, 4.5 lb-ft)
(b): 33 N.m (3.3 kg-m, 24.0 lb-ft)

Install new exhaust pipe gasket and exhaust pipe (1).

Tightening Torque
(a): 55 N.m (5.5 kg-m, 40.0 lb-ft)

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Install tie rod ends (1) to knuckles (2). Tighten castle nuts (3) until
holes for cotter pin (4) align but within specified torque and then
bend new cotter pins (4) as shown.
Tightening Torque
(a): 43 N·m (4.3 kg-m, 31.5 lb-ft)
NOTE:
Removed cotter pin should be replaced with new one.

Tighten tie rod end lock nuts (1) to specified torque.

Tightening Torque
(a): 45 N·m (4.5 kg-m, 32.5 lb-ft)
 MANUAL RACK AND PINION 3B-15

Be sure that steering wheel and brake discs (right and left) are
all straight ahead driving state and then insert steering lower
shaft into steering pinion shaft.

Tighten steering lower shaft bolts to specified torque (Lower bolt
(1) first, and then upper bolt (2)).
Tightening Torque
(a): 25 N.m (2.5 kg-m, 18.0 lb-ft)

Tighten wheel nuts (1) to specified torque.

Tightening Torque
(a): 85 N·m (8.5 kg-m, 61.5 lb-ft)

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After completion of installation, check wheel alignment and toe
setting referring to FRONT END ALIGNMENT in section 3A.

REQUIRED SERVICE MATERIALS

RECOMMENDED
MATERIAL USE
SUZUKI PRODUCT

Sliding part of rack against steering housing (All
around rack plunger, rack bushing and rack)

Sliding part against steering pinion
Lithium Grease
SUZUKI SUPER GREASE E (Oil seal lip, needle bearing)
(Should be applicable
(99000-25050)
Steering rack and pinion gear teeth
for –40
C~130
C)

Filled into pinion bearing plug

Contacting parts of tie rod and rack side boots

Rack end ball joint
3B-16 MANUAL RACK AND PINION

SPECIAL TOOL

09913-50121 09913-65210 09921-20200 09925-98210

Oil seal remover Tie-rod end remover Bearing remover Bearing installer

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09944-18211 09944-26011
09930-30104 09943-88211 Pinion torque checking Pinion bearing plug
Sliding shaft Bearing installer socket socket (43 mm)

09944-48210
Rack bush remover