STEERING

SECTION
STEERING SYSTEM
ST B

E
CONTENTS
HOW TO USE THIS MANUAL ...................... 2 STEERING WHEEL .......................................... 10 F
Exploded View .........................................................10
HOW TO USE THIS MANUAL ............................ 2 Removal and Installation .........................................10
Application Notice ..................................................... 2 ST
STEERING COLUMN ........................................ 12
PRECAUTION ............................................... 3 Exploded View .........................................................12
Removal and Installation .........................................12
PRECAUTIONS ................................................... 3 Inspection ................................................................14 H
Service Notice or Precautions for Steering System
...... 3 STEERING SHAFT ........................................... 15
Precautions for Removing Battery Terminal ............. 3 Exploded View .........................................................15 I
Removal and Installation .........................................15
PREPARATION ............................................ 4 Inspection ................................................................17
PREPARATION ................................................... 4 STEERING GEAR AND LINKAGE ................... 19 J
Special Service Tools ................................................ 4 Exploded View .........................................................19
Commercial Service Tools ........................................ 4 Removal and Installation .........................................21
Sealant or/and Lubricant ........................................... 4 Disassembly and Assembly .....................................23 K
Inspection ................................................................25
BASIC INSPECTION .................................... 6
SERVICE DATA AND SPECIFICATIONS
STEERING WHEEL ............................................. 6 L
Inspection .................................................................. 6 (SDS) ............................................................ 27

SYMPTOM DIAGNOSIS ............................... 8 SERVICE DATA AND SPECIFICATIONS

(SDS) ................................................................. 27 M
NOISE, VIBRATION AND HARSHNESS Steering Wheel ........................................................27
(NVH) TROUBLESHOOTING ............................. 8 Steering Angle .........................................................27
NVH Troubleshooting Chart ...................................... 8 Steering Column ......................................................27 N
Steering Shaft ..........................................................28
PERIODIC MAINTENANCE .......................... 9 Rack Stroke .............................................................28
Inner Socket Length ................................................28
STEERING WHEEL ............................................. 9 O
Swing Force .............................................................28
Inspection .................................................................. 9 Socket Axial End Play .............................................28
REMOVAL AND INSTALLATION ............... 10 P

Revision: 2014 August ST-1 AD0

 HOW TO USE THIS MANUAL
< HOW TO USE THIS MANUAL >
HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
Application Notice INFOID:0000000011450292

Check vehicle identification number to use the corresponding service information in this manual.

Service information Destination Vehicle identification number

TYPE A India Up to VIN: MDHZBAAD0E4 007126
TYPE B India From VIN: MDHZBAAD0E4 007127
*: Refer to GI-32, "Information About Identification or Model Code" to vehicle identification number

Revision: 2014 August ST-2 AD0

 PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Service Notice or Precautions for Steering System INFOID:0000000010037051
B
• In case of removing steering gear assembly, make the final tightening with grounded and unloaded vehicle
condition, and then check wheel alignment.
• Observe the following precautions when disassembling. C
- Before disassembly, thoroughly clean the outside of the unit.
- Disassembly should be done in a clean work area. It is important to prevent the internal parts from becoming
contaminated by dirt or other foreign matter. D
- For easier and proper assembly, place disassembled parts in order on a parts rack.
- Use nylon cloth or paper towels to clean the parts; common shop rags can leave lint that might interfere with
their operation.
- Never reuse non-reusable parts. E
- Before assembling, apply the specified grease to the directed parts.
• During quick steering, rasping noise may be heard from around the steering wheel. This is not a malfunction.
The noise is an operating noise of the EPS system under normal conditions. If the rasping noise occurs dur- F
ing slow steering, this may not be an operating noise of the system. In this case, it is necessary to find out
the location of the noise and repair, if necessary.
• Never repeat static steering. (Motor and EPS control unit could be heated.)
ST
Precautions for Removing Battery Terminal INFOID:0000000010037052

• When removing the 12V battery terminal, turn OFF the ignition H
switch and wait at least 30 seconds.
NOTE:
ECU may be active for several tens of seconds after the ignition
switch is turned OFF. If the battery terminal is removed before ECU I
stops, then a DTC detection error or ECU data corruption may
occur.
• For vehicles with the 2-batteries, be sure to connect the main bat- J
tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be
SEF289H
K
detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE: L
The removal of 12V battery may cause a DTC detection error.

Revision: 2014 August ST-3 AD0

 PREPARATION
< PREPARATION >
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000010037053

Tool number
Description
Tool name
ST3127S000 • Measuring steering column rotating torque
Preload gauge • Measuring pinion rotating torque

ZZA0806D

ST27180001 Removing steering wheel

Steering wheel puller

ZZA0819D

KV48103400 Measuring pinion rotating torque

Preload adapter

ZZA0824D

Commercial Service Tools INFOID:0000000010037054

Tool name Description

Ball joint remover Removing steering outer socket

S-NT146

Boot band crimping tool Installing boot clamp (large diameter)

ZZA1229D

Sealant or/and Lubricant INFOID:0000000010448037

Revision: 2014 August ST-4 AD0

 PREPARATION
< PREPARATION >
Name Description Note
A
Genuine Silicone grease, CP-3N or equivalent
Steering gear assembly inner socket —
(Power steering)
Genuine Lithium Soap, Idemitsu Autorex A, Dow
Steering gear assembly inner socket — B
corning 111 or equivalent (Manual steering)

ST

Revision: 2014 August ST-5 AD0

 STEERING WHEEL
< BASIC INSPECTION >
BASIC INSPECTION
STEERING WHEEL
Inspection INFOID:0000000010037055

NEUTRAL POSITION STEERING WHEEL

1. Check that steering gear assembly, steering column assembly and steering wheel are installed in the cor-
rect position.
2. Check wheel alignment within specification. Refer to FSU-8, "Inspection" (For India production models),
FSU-27, "Inspection" (For Indonesia production models).
3. Set vehicle to the straight-ahead position and confirm steering wheel is in the neutral position.
• Loosen outer socket lock nut and turn inner socket to left and right equally to make fine adjustments if
steering wheel is not in the neutral position.
CAUTION:
If the adjustment is performed by using the inner socket, check wheel alignment after the adjust-
ment. Refer to FSU-8, "Inspection" (For India production models), FSU-27, "Inspection" (For
Indonesia production models).
STEERING WHEEL TURNING FORCE
1. Park vehicle on a level and dry surface, set parking brake.
2. Tires need to be inflated normal pressure. Refer to WT-7, "Tire Air Pressure".
3. Start engine (Power steering).
4. Check steering wheel turning force when steering wheel has
been turned 360° from neutral position.

Steering wheel turning force : Refer to ST-27, "Steer-

ing Wheel".

SGIA1523J

FRONT WHEEL TURNING ANGLE

1. Perform toe-in inspection. Refer to FSU-8, "Inspection" (For India production models), FSU-27, "Inspec-
tion" (For Indonesia production models).
CAUTION:
Perform front wheel turning angle inspection, after toe-in inspection.
2. Place front wheels on turning radius gauges and rear wheels on
stands, so that vehicle can be level.
3. Check the maximum inner and outer wheel turning angles for LH
and RH road wheels.

FAA0016D

Revision: 2014 August ST-6 AD0

 STEERING WHEEL
< BASIC INSPECTION >
• With the engine at idle, turn steering wheel from full left stop to
full right stop and measure the turning angles. A

A : Inner wheel angle

B : Outer wheel angle B

Steering angle : Refer to ST-27, "Steering Angle".

C

SGIA0055E

D
• Check the following items when turning angle is out of the standard.
- Check rack stroke (L).
E
Rack stroke neutral position L : Refer to ST-28, "Rack
Stroke".
- Disassemble steering gear assembly to check the cause that F
rack stroke is outside of the standard.
• Steering angles are not adjustable. Check steering gear
assembly, steering column assembly and front suspension
ST
components for wear or damage if any of the turning angles
are different from the specified value. Replace any of them, if
any non-standard condition exists. JSGIA0272ZZ

Revision: 2014 August ST-7 AD0

 Symptom
Reference

×: Applicable

Revision: 2014 August

Steering
< SYMPTOM DIAGNOSIS >

Possible cause and SUSPECTED PARTS

NVH Troubleshooting Chart

Noise
Shake

Judder
Shimmy
Vibration
SYMPTOM DIAGNOSIS

Outer/inner socket ball joint swinging torque ST-25, "Inspection"

×
Outer/inner socket ball joint rotating torque ST-25, "Inspection"

ST-8
Outer/inner socket ball joint end play ST-25, "Inspection"

×
Steering wheel play ST-9, "Inspection"

×
Improper steering wheel —

×
×
×
Mounting looseness ST-19, "Exploded View"

×
×
×
×
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.

Steering column deformation or damage ST-14, "Inspection"

×
×
Improper installation or looseness of steering column ST-12, "Exploded View"

×
×
Steering linkage looseness ST-19, "Exploded View"

×
×
AXLE and SUSPENSION NVH in FAX, RAX, FSU, RSU section

×
×
×
×
×
TIRE NVH in WT section

×
×
×
×
×
ROAD WHEEL NVH in WT section

×
×
×
×
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

DRIVE SHAFT NVH in FAX section

×
×
×

BRAKE NVH in BR section

×
×
×
×
INFOID:0000000010037056

AD0
 STEERING WHEEL
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE A
STEERING WHEEL
Inspection INFOID:0000000010037057
B

STEERING WHEEL AXIAL END PLAY

1. Check installation conditions of steering gear assembly, front suspension assembly, axle and steering col- C
umn assembly.
2. Check if movement exists when steering wheel is moved up and down, to the left and right and to the axial
direction. D

Steering wheel axial end play : Refer to ST-27, "Steering Wheel".

3. Check the following items when steering wheel axial end play is out of the standard. E
• Check the steering column assembly mounting condition. Refer to ST-12, "Exploded View".
• Check steering gear assembly mounting condition for looseness. Refer to ST-19, "Exploded View".
STEERING WHEEL PLAY F
1. Turn steering wheel so that front wheels come to the straight-ahead position.
2. Start engine and lightly turn steering wheel to the left and right until front wheels start to move.
ST
3. Measure steering wheel movement on the outer circumference.

Steering wheel play on the : Refer to ST-27, "Steering Wheel". H

outer circumference
4. Check the following items when steering wheel play is out of the standard.
• Check backlash for each joint of steering column assembly. I
• Check installation condition of steering gear assembly.

Revision: 2014 August ST-9 AD0

 STEERING WHEEL
< REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION
STEERING WHEEL
Exploded View INFOID:0000000010037058

JSGIA1506GB

Steering column upper cover Combination switch Spiral cable

Steering wheel Horn pad Steering column lower cover
Steering column

N·m (kg-m, ft-lb)

: Always replace after every disassembly.

: Pawl.

Removal and Installation INFOID:0000000010037059

REMOVAL
NOTE:
When reconnecting spiral cable, fix cable with a tape so that fixing case and rotating part keep aligned. This
will omit neutral position alignment procedure during spiral cable installation.
1. Set vehicle to the straight-ahead position.
2. Remove the horn pad by pulling it gently.
3. Remove steering wheel lock nut after steering is locked.

Revision: 2014 August ST-10 AD0

 STEERING WHEEL
< REMOVAL AND INSTALLATION >
4. Remove steering wheel with the steering wheel puller (A) (SST:
ST27180001). A
NOTE:
Put paint marks on the steering wheel and the column shaft
head for supporting accurate positioning during the installation
B
procedure.

JSGIA0654ZZ

D
INSTALLATION
Note the following, and install in the reverse order of removal.
• Check the spiral cable neutral position after replacing or rotating spiral cable.
CAUTION: E
Never twist spiral cable excessively after it becomes tight. (Twisting may cause the cable to be torn
off.)
• Never reuse steering wheel lock nut. F
• Press gently to fix horn pad.
CAUTION:
Never press hard when assembling the horn pad to the steering wheel.
ST

Revision: 2014 August ST-11 AD0

 STEERING COLUMN
< REMOVAL AND INSTALLATION >
STEERING COLUMN
Exploded View INFOID:0000000010037060

MANUAL STEERING

JSGIA1546GB

Steering column assembly

N·m (kg-m, ft-lb)

POWER STEERING

JSGIA1547GB

Steering column assembly

N·m (kg-m, ft-lb)

Removal and Installation INFOID:0000000010037061

REMOVAL
CAUTION:
• Never impact on the axis when removing steering column assembly.
• Never repeat static steering. (Motor and EPS control unit could be heated.)
• Be careful when removing steering column assembly from the vehicle because it is heavy.
• Keep steering column assembly away from magnetic sources.
• Never disassemble steering column assembly. It is not separable.

Revision: 2014 August ST-12 AD0

 STEERING COLUMN
< REMOVAL AND INSTALLATION >
• While removing the steering column assembly, never move the steering gear.
• When removing the steering column assembly, be careful not to allow the intermediate shaft to turn. A
1. Set vehicle to the straight-ahead position.
2. Remove steering wheel. Refer to ST-10, "Removal and Installation".
3. Remove steering column cover. Refer to IP-12, "Removal and Installation". B
4. Remove spiral cable. Refer to ST-10, "Removal and Installation".
5. Remove combination switch. Refer to BCS-50, "Removal and Installation".
C
6. Disconnect each switch harness connectors installed to steering column assembly.
7. Loosen yoke mounting bolt (intermediate shaft side).
D

JSGIA1490ZZ

ST
8. Remove intermediate shaft mounting bolt (steering column
side), and separate intermediate shaft from steering column
assembly. Refer to ST-15, "Removal and Installation".
H

J
JSGIA1491ZZ

CAUTION:
K
• Place a matching mark on both intermediate shaft
and steering column assembly before removing inter-
mediate shaft.
• When removing intermediate shaft, never insert a tool, L
such as a screwdriver, into the yoke groove to pull out the
intermediate shaft. In case of the violation of the above,
replace intermediate shaft with a new one. M
9. Disconnect EPS control unit connectors (For Power steering).
Refer to STC-38, "Removal and Installation".
10. Remove steering column assembly. Refer to ST-12, "Exploded N
View". JSGIA1008ZZ

CAUTION:
When removing the mounting, be careful not to drop the steering column assembly.
O
11. Remove EPS control unit from steering column assembly (For Power steering). Refer to STC-38,
"Removal and Installation".
12. Perform inspection after removal. Refer to ST-14, "Inspection".
P
INSTALLATION
CAUTION:
• Never impact on the axis when removing steering column assembly.
• When installing the steering column cover, check that the vehicle harness is not stuck in the cover.
Note the following, and install in the reverse order of removal.
• For intermediate shaft mounting bolt direction, refer to ST-15, "Exploded View". (Do not insert it from the
other side.)

Revision: 2014 August ST-13 AD0

 STEERING COLUMN
< REMOVAL AND INSTALLATION >
• When connecting intermediate shaft upper side and column
shaft, make sure the bolt is securely seated in groove of column
shaft before final tightening.
• Align matching mark between steering shaft and steering column
assembly before final tighting.
• After installing steering column assembly, perform self-diagnosis
with CONSULT to ensure correct operation (For Power steering).
Refer to STC-9, "CONSULT Function".
• Perform inspection after installation. Refer to ST-14, "Inspection".

SGIA1295E

Inspection INFOID:0000000010037062

INSPECTION AFTER REMOVAL

• Check each part of steering column assembly for damage or other malfunctions. Replace if there are any
abnormal conditions.
• Measure steering column rotating torque using a preload gauge
(A) (SST: ST3127S000). Replace steering column assembly if the
rotating torque is outside the standard.

Rotating torque : Refer to ST-27, "Steering Column".

JPGIA0085ZZ

• Measure the length (L) shown in the figure, if vehicle has been
involved in a minor collision. Replace steering column assembly
(with motor, reduction gear, sensor) if (L) is outside the standard
(For Power steering).

Steering column length L : Refer to ST-27, "Steering

Column".

JSGIA1460ZZ

• Measure the length (L) shown in the figure, if vehicle has been
involved in a minor collision. Replace steering column assembly if
(L) is outside the standard (For manual steering).

Steering column length L : Refer to ST-27, "Steering

Column".

JSGIA0932ZZ

INSPECTION AFTER INSTALLATION

• Check each part of steering column assembly for damage or other malfunctions. Replace if there are any
abnormal conditions.
• Check the steering wheel play, neutral position steering wheel, steering wheel turning force, and front wheel
turning angle. Refer to ST-9, "Inspection".

Revision: 2014 August ST-14 AD0

 STEERING SHAFT
< REMOVAL AND INSTALLATION >
STEERING SHAFT
A
Exploded View INFOID:0000000010037063

MANUAL STEERING B

ST
JSGIA1613GB

Lower joint Steering shaft Steering column assembly

H
N·m (kg-m, in-lb)

POWER STEERING
I

N
JSGIA1614GB

Lower joint Steering shaft Steering column assembly

O
N·m (kg-m, in-lb)

Removal and Installation INFOID:0000000010037064

P
REMOVAL
CAUTION:
Spiral cable may be cut if steering wheel turns while separating steering column assembly and steer-
ing gear assembly. Be sure to secure steering wheel using string to avoid turning.
1. Set vehicle to the straight-ahead position.

Revision: 2014 August ST-15 AD0

 STEERING SHAFT
< REMOVAL AND INSTALLATION >
2. Loosen lower joint mounting bolt (steering shaft side).

JSGIA1490ZZ

3. Remove lower joint mounting bolt (steering gear side).

JSGIA1493ZZ

4. Separate lower joint from steering gear assembly.

CAUTION:
• Place a matching mark on both yoke and steering gear
assembly before removing lower joint.
• When removing yoke, never insert a tool, such as a
screwdriver, into the yoke groove to pull out the yoke. In
case of the violation of the above, replace yoke with a new
one.
5. Remove lower joint from steering shaft.

JSGIA1018ZZ

6. Remove steering shaft mounting bolt (steering column side),

and remove steering shaft from steering column assembly.

JSGIA1491ZZ

CAUTION:

Revision: 2014 August ST-16 AD0

 STEERING SHAFT
< REMOVAL AND INSTALLATION >
• Place a matching mark on both steering shaft and
steering column assembly before removing steering A
shaft.
• When removing steering shaft, never insert a tool, such
as a screwdriver, into the yoke groove to pull out the B
steering shaft. In case of the violation of the above,
replace steering shaft with a new one.
7. Perform inspection after removal. Refer to ST-17, "Inspection".
C

JSGIA1008ZZ

D
INSTALLATION
CAUTION:
Spiral cable may be cut if steering wheel turns while separating steering column assembly and steer-
ing gear assembly. Be sure to secure steering wheel using string to avoid turning. E
Note the following, and install in the reverse order of removal.
• For steering shaft mounting bolt, and yoke mounting bolt direction, refer to ST-15, "Exploded View". (Do not
insert it from the other side.) F
• To install align the guide protrusion with the groove of yoke ,
make sure the bolt is securely seated in groove of steering gear
before final tightening.
ST
CAUTION:
If a guide protrusion is not included, align with the matching
mark placed at the removal step.
• When tightening yoke mounting bolt (steering gear assembly side), H
tighten it by hand first, and make sure there is no feeling of sticking
or galling before final tightening.
I
JPGIA0041ZZ

• When connecting steering shaft upper side and column shaft, J

make sure the bolt is securely seated in groove of column shaft
before final tightening.
• Align matching mark between steering shaft and steering column
K
assembly before final tightening.
• Perform inspection after installation. Refer to ST-17, "Inspection".

SGIA1295E M
Inspection INFOID:0000000010037065

INSPECTION AFTER REMOVAL N

• Check each part of lower joint for damage or other malfunctions. Replace if there are any abnormal condi-
tions.
• Check each part of steering shaft for damage or other malfunctions. Replace if there are any abnormal con- O
ditions.

Revision: 2014 August ST-17 AD0

 STEERING SHAFT
< REMOVAL AND INSTALLATION >
• Measure the length (A) shown in the figure, if vehicle has been
involved in a minor collision. Replace steering shaft if (A) is outside
the standard.

Steering shaft length A : Refer to ST-28, "Steering

Shaft"

JSGIA1027ZZ

INSPECTION AFTER INSTALLATION

• Check each part of lower joint for damage or other malfunctions. Replace if there are any abnormal condi-
tions.
• Check each part of steering shaft for damage or other malfunctions. Replace if there are any abnormal con-
ditions.
• Rotate steering wheel to check for decentered condition, binding, noise, or excessive steering effort.
• Check the steering wheel play, neutral position steering wheel, steering wheel turning force, and front wheel
turning angle. Refer to ST-9, "Inspection", ST-6, "Inspection".

Revision: 2014 August ST-18 AD0

 STEERING GEAR AND LINKAGE
< REMOVAL AND INSTALLATION >
STEERING GEAR AND LINKAGE
A
Exploded View INFOID:0000000010037066

REMOVAL B
MANUAL STEERING
C

ST
JSGIA1526GB

Guide Steering gear assembly Heat insulator

Front suspension member
H

:Vehicle front
: Always replace after every disassembly. I
:N·m (kg-m, ft-lb)

:N·m (kg-m, in-lb)

J
POWER STEERING

JSGIA1527GB
O

Guide Steering gear assembly Heat insulator

Front suspension member P
: :Vehicle front
: Always replace after every disassembly.

:N·m (kg-m, ft-lb)

DISASSEMBLY

Revision: 2014 August ST-19 AD0

 STEERING GEAR AND LINKAGE
< REMOVAL AND INSTALLATION >
MANUAL STEERING

JSGIA1528GB

Fire wall seal Joint cover Outer socket

Lock nut Boot clamp (small diameter) Boot
Boot clamp (large diameter) Inner socket Gear housing assembly

: :Vehicle front
:Apply Genuine Lithium Soap, Autorex A (manufactured by Kyodo yushi), Dow corning 111 or equivalent.
:Always replace after every disassembly

:N·m (kg-m, ft-lb)

Revision: 2014 August ST-20 AD0

 STEERING GEAR AND LINKAGE
< REMOVAL AND INSTALLATION >
POWER STEERING
A

ST

H
JSGIA1463GB

Firewall seal Gear housing assembly Outer socket

Lock nut Boot clamp (small diameter) Boot I
Boot clamp (large diameter) Inner socket

: :Vehicle front J
:Apply Genuine Silicon grease, CP-3N or equivalent.
:Always replace after every disassembly
K
:N·m (kg-m, ft-lb)

Removal and Installation INFOID:0000000010037067

L

REMOVAL
1. Set vehicle to the straight-ahead position. M
2. Loosen lower joint mounting bolt (intermediate shaft side).

P
JSGIA1490ZZ

Revision: 2014 August ST-21 AD0

 STEERING GEAR AND LINKAGE
< REMOVAL AND INSTALLATION >
3. Remove lower joint mounting bolt (steering gear assembly
side). Refer to ST-12, "Removal and Installation".
CAUTION:
• Spiral cable may be cut if steering wheel turns while sepa-
rating steering column assembly and steering gear
assembly. Always fix the steering wheel using string to
avoid turning.
• Place a matching mark on both lower joint and steering
gear assembly before removing lower joint.
• When removing lower joint, never insert a tool, such as a
screwdriver, into the yoke groove to pull out the lower JSGIA1493ZZ
joint. In case of the violation of the above, replace lower
joint with a new one.
4. Remove tires. Refer to WT-5, "Removal and Installation".
5. Remove steering outer socket from steering knuckle so as not to
damage ball joint boot using suitable ball joint remover (com-
mercial service tool).
CAUTION:
Temporarily tighten the nut to prevent damage to threads
and to prevent the ball joint remover from sudden drop
turning.

SGIA0184J

6. Support front suspension member with a suitable jack.

CAUTION:
Check that jack supporting status is stable.
7. Remove rear torque rod. Refer to EM-79, "Removal and Installa-
tion".
8. Remove font suspension member mounting bolts. Refer to FSU-
18, "Removal and Installation" (For India production models),
FSU-37, "Removal and Installation" (For Indonesia production
models).

JSGIA1012ZZ

9. Remove the mounting bolts and nuts of steering gear assem-

bly.

JSGIA1497ZZ

Revision: 2014 August ST-22 AD0

 STEERING GEAR AND LINKAGE
< REMOVAL AND INSTALLATION >
10. Lower the suitable jack to the position where the steering gear
assembly can be removed. A
CAUTION:
• Secure front suspension member to a jack.
• Operate while checking that jack supporting status is sta-
B
ble.

JSGIA1014ZZ

D
11. Remove guide from pinion assembly.

ST
JSGIA1015ZZ

12. Remove heat insulator . H

JSGIA1016ZZ
K

INSTALLATION
Note the following, and install in the reverse order of removal. L
CAUTION:
• Spiral cable may be cut if steering wheel turns while separating steering column assembly and steer-
ing gear assembly. Always fix the steering wheel using string to avoid turning.
• The guide protrusion is not mandatory to be reinstalled. M
• Clean mounting surface on the body side of fire wall seal when installing steering gear assembly.
• Perform final tightening of nuts and bolts on each part under unladen conditions with tires on level ground
when removing steering gear assembly. Check wheel alignment. Refer to FSU-8, "Inspection" (For india pro- N
duction models), FSU-27, "Inspection" (For Indonesia models).
• Rotate steering wheel to check for decentered condition, binding, noise or excessive steering effort.
• Never reuse steering outer socket mounting nut and fire wall seal.
• Perform inspection after installation. Refer to ST-25, "Inspection". O

Disassembly and Assembly INFOID:0000000010037068

P
DISASSEMBLY
CAUTION:
• Disassemble and assemble steering gear assembly by fixing the mounting area with a vise using
copper plates.
• Clean steering gear assembly with kerosene before disassembling.
1. Loosen outer socket lock nut, and remove outer socket.
CAUTION:

Revision: 2014 August ST-23 AD0

 STEERING GEAR AND LINKAGE
< REMOVAL AND INSTALLATION >
When loosening lock nut, be sure to fix outer socket with a wrench or an equivalent to prevent ball
joint from getting contact with knuckle.
2. Remove boot clamps, and then remove boot from inner socket.
CAUTION:
Never damage inner socket and gear housing assembly when removing boot. Inner socket and
gear housing assembly must be replaced if inner socket and gear housing assembly are damaged
because it may cause foreign material interfusion.
3. Remove inner socket from gear housing assembly.
4. Remove firewall seal from gear housing assembly.
5. Remove joint cover from gear housing assembly (Manual steering).
6. Perform inspection after disassembly. Refer to ST-25, "Inspection".
ASSEMBLY
1. Install inner socket to rack.
2. Decide on the neutral position for the rack stroke (L).

Rack stroke neutral position L : Refer to ST-28, "Rack

Stroke".

JSGIA0272ZZ

3. Apply recommended grease to inner socket and install boot

to gear housing assembly and inner socket.
NOTE:
• Use Genuine Lithium Soap, Idemitsu Autorex A, Dow
corning 111 or equivalent for manual steering.
• Use Genuine Silicone grease,CP-3N or equivalent for
power steering.
CAUTION:
Never reuse boot.

Grease application position (Reference)

JPGIA0102ZZ
B (Manual steering) : 10 mm (0.39 in)
B (Power steering) : 19 mm (0.75 in)

4. Install boot clamp (large diameter) to boot using boot band

crimping tool (SST: KV40107300).
CAUTION:
• Never reuse boot clamp (large diameter).
• Install boot clamp (large diameter) securely to boot
groove, and crimp it so as to have clearance of 3 mm (0.12
in) or less (Manual steering) and 8 mm (0.31 in) or less
(Power steering) as shown.
5. Install boot clamp (small diameter) to boot.
CAUTION:
Never reuse boot clamp (small diameter). SGIA1302E

Revision: 2014 August ST-24 AD0

 STEERING GEAR AND LINKAGE
< REMOVAL AND INSTALLATION >
6. Install joint cover to gear housing assembly (Manual steer-
ing). A
CAUTION:
Make sure that joint cover is attached as shown in the fig-
ure.
B

JPGIA0057ZZ

D
7. Align the projection of fire wall seal with the groove of
gear housing assembly , and install fire wall seal to gear hous-
ing assembly (for power steering). E
CAUTION:
Never reuse fire wall seal.

ST
JSGIA1223ZZ

8. Adjust inner socket to standard length (L), and then tighten lock
H
nut to the specified torque. Check length again after tighten-
ing lock nut.

Inner socket length L : Refer to ST-28, "Rack I

Stroke".
CAUTION:
J
• If the lock nut has a marking, install the lock nut to the
inner socket with the unmarked side faced the outer
socket side.
JPGIA0187ZZ
K

• When tightening the lock nut , be sure to fix outer

socket with a wrench or an equivalent to prevent the L
ball joint from getting contact with the knuckle.
• Adjust toe-in after this procedure. The length achieved
after toe-in adjustment is not necessary the above value.
M

JSGIA0538ZZ

Inspection INFOID:0000000010037069
O

INSPECTION AFTER DISASSEMBLY

P
Boot
• Check boot for cracks, and replace it if a malfunction is detected.
Gear Housing Assembly
• Check gear housing assembly for damage and scratches (inner wall). Replace if there are any abnormal
conditions.
Outer Socket and Inner Socket

Revision: 2014 August ST-25 AD0

 STEERING GEAR AND LINKAGE
< REMOVAL AND INSTALLATION >
• Check the following items and replace the component if it does not meet the standard.
BALL JOINT SWINGING FORCE
• Hook a spring balance at the point shown in the figure and pull the
spring balance. Make sure that the spring balance reads the spec-
ified value when ball stud and inner socket start to move. Replace
outer socket and inner socket if they are outside the standard.

Measuring point of outer socket : Ball stud upper side

Measuring point of inner socket : Point shown in the figure

Swinging force : Refer to ST-28, "Swing Force".

JPGIA0188ZZ
BALL JOINT AXIAL END PLAY
• Apply an axial load of 490 N (50 kg, 110 lb) to ball stud. Using a
dial gauge, measure amount of stud movement, and then make
sure that the value is within the following specified range. Replace
outer socket and inner socket if the measured value is out-
side the standard.

Axial end play : Refer to ST-28, "Socket Axial End

Play".

JSGIA0109ZZ

INSPECTION AFTER INSTALLATION

• Check if steering wheel turns smoothly when it is turned several times fully to the end of the left and right.
• Check the steering wheel play, neutral position steering wheel, steering wheel turning force, and front wheel
turning angle. Refer to ST-6, "Inspection", ST-9, "Inspection".
• Check wheel alignment. Refer to FSU-8, "Inspection" (For India production models), FSU-27, "Inspection"
(For Indonesia production models).

Revision: 2014 August ST-26 AD0

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) A
SERVICE DATA AND SPECIFICATIONS (SDS)
Steering Wheel INFOID:0000000010037071
B

Item Standard
C
Steering wheel axial end play 0 mm (0 in)
Steering wheel play on the outer circumference 0 - 35 mm (0 - 1.38 in)
Steering wheel turning force 36 N (3.7 kg-f, 8.09 lb-f) or less D

Steering Angle INFOID:0000000010037072

E
FOR INDIA
Power steering models
F
Standard
Item For 2 row Seat models For 3 row seat models
Type A Type B – ST
Minimum 39° 00′ (39.0°) 41° 30′ (41.5°) 41° 30′ (41.5°)
Inner wheel Nominal 42° 00′ (42.0°) 44° 30′ (44.5°) 44° 30′ (44.5°)
H
Maximum 43° 00′ (43.0°) 45° 30′ (45.5°) 45° 30′ (45.5°)
Outer wheel Nominal 34° 30′ (34.5°) 36° 30′ (36.5°) 36° 30′ (36.5°)
NOTE: I
About the type, refer to ST-2, "Application Notice".
Manual steering models
J
Standard
Item
For 2 row Seat models For 3 row seat models
K
Minimum 39° 00′ (39.0°) 41° 30′ (41.5°)
Inner wheel Nominal 42° 00′ (42.0°) 44° 30′ (44.5°)
Maximum 43° 00′ (43.0°) 45° 30′ (45.5°) L
Outer wheel Nominal 34° 30′ (34.5°) 36° 30′ (36.5°)

EXCEPT FOR INDIA M

Unit: Degree minute (Decimal degree)

Item Standard
Minimum 41° 30′ (41.5°) N
Inner wheel Nominal 44° 30′ (44.5°)
Maximum 45° 30′ (45.5°)
O
Outer wheel Nominal 36° 30′ (36.5°)

Steering Column INFOID:0000000010037073

Item Standard
Rotating torque 0 – 1.5 N·m (0 – 0.15 kg-m, 0 – 13 in-lb)
Manual steering 451.4 – 455.4 mm (17.77 – 17.93 in)
Steering column length*
Power steering 451.4 – 456.4 mm (17.77 – 17.97 in)
*: For measuring position, refer to ST-14, "Inspection".

Revision: 2014 August ST-27 AD0

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
Steering Shaft INFOID:0000000010037074

Item Standard
Manual steering 85.5 – 86.5 mm (3.366 – 3.406 in)
Intermediate shaft length*
Power steering 86.7 – 88.7 mm (3.413 – 3.492 in)
*:For measuring position, Refer to ST-17, "Inspection"
Rack Stroke INFOID:0000000011450576

FOR INDIA
Power steering models

Unit: mm (in)

Standard
Item For 2 row models For 3 row models
Type A Type B –
Rack stroke neutral position 68.5 mm (2.67 in) 71.5 mm (2.82 in) 71.5 mm (2.82 in)
NOTE:
About the type, refer to ST-2, "Application Notice".
Manual steering models
Unit: mm (in)

Standard
Item
For 2 row models For 3 row models
Rack stroke neutral position 68.5 mm (2.67 in) 71.5 mm (2.82 in)

EXCEPT FOR INDIA

Unit: mm (in)

Item Standard
Rack stroke neutral position 71.5 mm (2.82 in)

Inner Socket Length INFOID:0000000011450577

Unit: mm (in)

Item Standard
Manual steering 67.3 mm (2.65 in)
Inner socket length
Power steering 64.0 mm (2.52 in)

Swing Force INFOID:0000000011450664

Item Standard
Outer socket ball joint 6.0 – 54.7 N (0.61 – 5.6 kg-f, 1.35 – 12.29 lb-f)
Inner socket ball joint 3.5 – 34.7 N (0.36 – 3.5 kg-f, 0.79 – 7.8 lb-f)

Socket Axial End Play INFOID:0000000011450578

Unit: mm (in)

Item Standard
Outer socket 0.5 mm (0.020 in) or less
Inner socket 0.2 mm (0.008 in) or less

Revision: 2014 August ST-28 AD0