steering LEXUS ES300 2005 Manual PDF
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 746 of 969
F41497
SST
F41498
SST
F40050
Matchmarks
ZK8184
51-24
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2599 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
17. REMOVE STEERING LEFT TURN PRESSURE TUBE
(a) Using SST, remove the steering left turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the steering left turn pressure
tube.
18. REMOVE STEERING RIGHT TURN PRESSURE TUBE
(a) Using SST, remove the steering right turn pressure tube.
SST 09023-38201
(b) Remove the 2 O-rings from the steering right turn pres-
sure tube.
19. FIX RACK & PINION POWER STEERING GEAR ASSY
(a) Using SST, secure the rack & pinion power steering gear
assy.
SST 09612-00012
HINT:
Tape the SST before use.
20. REMOVE TIE ROD ASSY LH
(a) Place matchmarks on the tie rod assy LH and steering
rack end sub-assy.
(b) Loosen the lock nut, and remove the tie rod assy LH and
lock nut.
21. REMOVE TIE ROD ASSY RH
HINT:
Remove the RH side by the same procedures with LH side.
22. INSPECT TIE ROD ASSY LH
(a) Secure the tie rod assy LH in a vise.
(b) Install the nut to the stud bolt.
(c) Flip the ball joint stud back and forth 5 times.
(d) Using a torque wrench, turn the nut continuously at a rate
of 2 - 4 seconds per 1 turn and take the torque reading
of the 5th turn.
Turning torque:
0.83 - 3.43 NVm (8.5 - 35.0 kgfVcm, 7.3 - 30.4 in.Vlbf)
23. INSPECT TIE ROD ASSY RH
HINT:
Remove the RH side by the same procedures with LH side.
Page 747 of 969
C83166
Claw
Washer
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-25
2600 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
24. REMOVE STEERING RACK BOOT CLIP
(a) Remove the 2 steering rack boot clips.
25. REMOVE STEERING RACK BOOT NO.2 CLAMP
(a) Using pliers, remove the steering rack boot No.2 clamp.
NOTICE:
Be careful not to damage the steering rack boot No.2.
26. REMOVE STEERING RACK BOOT NO.1 CLAMP
HINT:
Remove the steering rack boot No.1 clamp by the same procedures with the steering rack boot No.2 clamp.
NOTICE:
Be careful not to damage the steering rack boot No.1.
27. REMOVE STEERING RACK BOOT NO.2
(a) Remove the steering rack boot No.2.
28. REMOVE STEERING RACK BOOT NO.1
HINT:
Remove the steering rack boot No.1 by the same procedures with the steering rack boot No.2.
29. REMOVE STEERING RACK END SUB-ASSY
(a) Using a screwdriver and a hammer, unstake the claw
washer.
NOTICE:
Avoid any impact to the power steering rack.
Page 748 of 969
F41526
SST
SST
SST
F41500
SST
F41501
Rack Guide
Spring Cap
SST
F41502
51-26
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2601 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using 2 SSTs, remove the 2 steering rack ends sub-assy
and 2 claw washers.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the il-
lustration.
Securely hold the steering rack end sub-assy with a
SST.
30. REMOVE RACK GUIDE
(a) Using SST, remove the rack guide spring cap nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
(b) Using SST, remove the rack guide spring cap.
SST 09631-10021
(c) Remove the compression spring and rack guide.
31. REMOVE POWER STEERING CONTROL VALVE
(a) Using a socket wrench (27 mm), remove the rack housing
cap.
Page 749 of 969
F41503
SST
F41504
Vinyl Tape
F41505
F41506
Vinyl Tape
R11572
Control Valve Ring
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-27
2602 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using SST, hold the control valve and remove the nut.
SST 09616-0001 1
(c) Wind vinyl tape around the serrated part of the control
valve.
(d) Remove the dust cover from the control valve housing.
(e) Remove the 2 bolts and control valve housing.
(f) Remove the gasket.
(g) To prevent oil seal lip damage, wind vinyl tape around the
serrated part of the control valve.
(h) Using a plastic hammer, remove the control valve with oil
seal from the control valve housing.
(i) Remove the oil seal from the control valve.
(j) Using a screwdriver, remove the 4 control valve rings.
NOTICE:
Be careful not to damage the grooves for the control valve
ring.
Page 750 of 969
F40911
SST
C83179
Wire Cylinder End
Stopper
F40542
SST
51-28
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2603 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
32. REMOVE POWER STEERING CONTROL VALVE
UPPER OIL SEAL
(a) Using SST and a press, remove the control valve upper
bearing and power steering control valve upper oil seal
from the control valve housing.
SST 09950- 70010 (09951- 07150), 09950- 60010
(09951-00250)
33. REMOVE CYLINDER END STOPPER
(a) Using a screwdriver and a hammer, turn the cylinder end
stopper clockwise until the wire end is visible through the
service hole.
(b) Using a screwdriver and a hammer, turn the cylinder end
stopper counterclockwise, and remove the wire and cylin-
der end stopper.
34. REMOVE POWER STEERING RACK
(a) Remove the power steering rack and power steering rack bush.
35. REMOVE POWER STEERING RACK BUSH
(a) Remove the power steering rack bush from the power
steering rack.
(b) Using SST, remove the rack bush oil seal.
SST 09527-2101 1, 09612-24014 (09613-22011)
(c) Using a screwdriver, remove the O-ring from the power
steering rack bush.
Page 751 of 969
ZX9355
F40544
SST
R10955
C03629
N00401
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-29
2604 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
36. INSPECT POWER STEERING RACK
(a) Using a dial indicator, check the power steering rack for
runout and for teeth wear and damage.
Maximum runout: 0.3 mm (0.012 in.)
(b) Check the back surface for wear and damage.
37. REMOVE POWER STEERING CYLINDER TUBE OIL
SEAL
(a) Using SST and a press, remove the power steering cylin-
der tube oil seal.
SST 09950- 70010 (09951- 07360), 09950- 60010
(09951-00290)
38. REMOVE RACK STEERING PISTON RING
(a) Using a screwdriver, remove the rack steering piston ring
and O-ring.
NOTICE:
Be careful not to damage the grooves for rack steering pis-
ton ring.
39. INSTALL RACK STEERING PISTON RING
(a) Coat a new O-ring with power steering fluid and install it
to the power steering rack.
(b) Expand a new rack steering piston ring with your fingers.
NOTICE:
Be careful not to over expand the rack steering piston ring.
(c) Coat the new rack steering piston ring with power steering
fluid.
(d) Install the rack steering piston ring to the power steering
rack, and settle it down with your fingers.
Page 752 of 969
F40545
SST
SST
W02101
Rack Teeth End
SST
F40543
SST 51-30
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2605 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
40. INSTALL POWER STEERING CYLINDER TUBE OIL
SEAL
(a) Coat a new power steering cylinder tube oil seal lip with
power steering fluid.
SST 09950- 60010 (09951- 00420, 09951- 00250,
09952-06010), 09950-70010 (09951-07360)
(b) Using SST and a press, install the power steering cylinder
tube oil seal.
NOTICE:
Make sure that the power steering cylinder tube oil
seal is installed facing in the correct direction.
Take care so that the power steering cylinder tube oil
seal will not be reversed as you install it.
41. INSTALL POWER STEERING RACK
(a) Install SST to the power steering rack.
SST 09631-33010
HINT:
If necessary, scrape the burrs off the power steering rack teeth
end and burnish.
(b) Coat the SST with power steering fluid.
(c) Install the power steering rack into the rack housing.
(d) Remove the SST.
42. INSTALL POWER STEERING RACK BUSH
(a) Using SST and a press, install the rack bush oil seal to the
power steering rack bush.
SST 09950- 60010 (09951- 00400), 09950- 70010
(09951-07100)
NOTICE:
Make sure that the rack bush oil seal is installed facing in
the correct direction.
(b) Coat a new O-ring with power steering fluid and install it
to the power steering rack bush.
Page 753 of 969
F05730
Vinyl Tape
Power
Steering
Bush
F40546
Cylinder
End Stopper
Wire
F41507
SST
F40912
SST
SST
F40913
SST
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-31
2606 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(c) To prevent rack bush oil seal lip damage, wind vinyl tape
around the power steering rack end, and apply power
steering fluid.
(d) Install the power steering rack bush to the power steering
rack.
43. INSTALL CYLINDER END STOPPER
(a) Align the installation hole for the wire of the cylinder end
stopper with the slot of the rack housing.
(b) Install a new wire into the cylinder end stopper.
(c) Using a screwdriver, turn the cylinder end stopper clock-
wise by 450 50.
44. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631-12071 (09633-00010)
(b) Apply vacuum of 53 kPa (400 mmHg, 15.75 in.Hg) for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is a change in the vacuum, check the installation of the
oil seals.
45. I N S TA L L P O W E R S T E E R I N G C O N T R O L VA LV E
UPPER OIL SEAL
(a) Coat a control valve upper bearing and a new power
steering control valve upper oil seal with power steering
fluid.
(b) Using SST and a press, install the power steering control
valve upper oil seal.
SST 09950- 70010 (09951- 07150), 09950- 60010
(09951-00180, 09952-06010, 09951-00320)
(c) Using SST and a press, install the control valve upper
bearing.
SST 09950- 70010 (09951- 07150), 09950- 60010
(09951-00180, 09952-06010, 09951-00340)
Page 754 of 969
C03629
R11573
SST
Valve Ring
F41508
Vinyl Tape
F41509
SST
F41512
51-32
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2607 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
46. INSTALL POWER STEERING CONTROL VALVE
(a) Expand 4 new control valve rings with your fingers.
NOTICE:
Be careful not to over expand the control valve ring.
(b) Coat the 4 control valve rings with power steering fluid.
(c) Install the 4 control valve rings to the control valve, and
settle them down with your fingers.
(d) Carefully slide the tapered end of SST over the control
valve rings until they fit to the control valve.
SST 09631-20081
NOTICE:
Be careful not to damage the control valve rings.
(e) To prevent power steering control valve upper oil seal lip
damage, wind vinyl tape around the serrated part of the
control valve.
(f) Coat the power steering control valve upper oil seal lip
with power steering fluid.
(g) Install the control valve to the control valve housing.
NOTICE:
Be careful not to damage the control valve ring and power
steering control valve upper oil seal lip.
(h) Coat a new oil seal lip with power steering fluid.
(i) Using SST and a press, install the oil seal.
SST 09612-2201 1
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
(j) Apply grease to the needle bearing.
(k) Install a new gasket to the control valve housing.
(l) Wind vinyl tape around the serration part of the control
valve.
(m) Install the control valve housing to the rack housing with
the 2 bolts.
Torque: 21 NVm (214 kgfVcm, 15 ftVlbf)
Page 755 of 969
F41513
SST
F41502
F41608
F41514SST
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-33
2608 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(n) Using SST, stop the control valve rotation and install a
new lock nut.
Torque: 24.5 NVm (250 kgfVcm, 18 ftVlbf)
SST 09616-0001 1
(o) Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
(p) Using a socket wrench (27 mm), install the rack housing
cap.
Torque: 58.5 NVm (597 kgfVcm, 43 ftVlbf)
(q) Using a punch and a hammer, stake the rack housing cap
and rack housing.
47. INSTALL RACK GUIDE
(a) Apply molybdenum disulfide lithium base grease to the rack guide.
(b) Install the rack guide.
(c) Install the compression spring.
(d) Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(e) Temporarily install the rack guide spring cap.
48. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH steering rack
ends sub-assy.
(b) Using SST, torque the rack guide spring cap.
SST 09631-10021
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)