LEXUS ES300 2005 Repair Manual
Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 741 of 969
F41889
Rack Housing
Rack Housing Cap
Gasket
Control Valve
Steering Right Turn
Pressure Tube
Steering Left Turn
Pressure Tube
O-Ring
Dust Cover
Control Valve
Housing
Power Steering
Control Valve
Upper Oil Seal
Control Valve Upper
Bearing
Control Valve Ring
Rack Guide
Spring Cap Nut
Rack Guide Spring Cap
Rack Guide
Compression
Spring
RACK & PINION POWER STEERING GEAR ASSY:
* For use with SST Non-reusable part
NVm (kgfVcm, ftVlbf) : Specified torque
Molybdenum disulfide lithium base grease
Precoated part
Power steering fluid
MP grease
Oil Seal
12.5 (127, 9)
*11.5 (117, 8)
12.5 (127, 9)
*11.5 (117, 8)
21 (214, 15)
68.5 (699, 51)
*48 (489, 35)
58.5 (597, 43)
24.5 (250, 18)
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-19
2594 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 742 of 969
F41890
Steering Rack
Boot No.1 ClampSteering Rack
Boot No.1
Lock Nut
Steering Rack Boot
Clip
Rack Housing
Claw Washer
Steering Rack End Sub-assy
Power Steering Cylinder
Tube Oil Seal
Power Steering Rack
O-Ring Rack Steering
Piston Ring
O-Ring
Power Steering Rack Bush Cylinder End Stopper
Wire
Claw Washer
Steering Rack End Sub-assy
Steering Rack Boot No.2 Clamp Steering Rack
Boot No.2
Steering Rack Boot ClipLock Nut
Tie Rod Assy RH
RACK & PINION GEAR POWER STEERING GEAR ASSY:
* For use with SST Non-reusable part
NVm (kgfVcm, ftVlbf) : Specified torque
Molybdenum disulfide lithium base grease
Power steering fluid
Tie Rod Assy LH
Rack Bush
Oil Seal
74 (755, 55)
83.5 (851, 62)
*58.5 (597, 43)
83.5 (851, 62)
*58.5 (597, 43)
74 (755, 55)
51-20
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2595 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 743 of 969
5106B-04
F40531
SST
C92274
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-21
2596 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
OVERHAUL
NOTICE:
When installing , coat the parts indicated by the arrow with power steering fluid or molybdenum disul-
fide lithium base grease (See page 51-18).
1. PRECAUTION(See page 60-1)
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE HORN BUTTON ASSY
(See page 60-22)
4. REMOVE STEERING WHEEL ASSY
(See page 50-8)
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
5. REMOVE FRONT WHEEL
6. REMOVE SPIRAL CABLE SUB-ASSY
(See page 50-8)
7. DISCONNECT TIE ROD ASSY LH
(a) Remove the cotter pin and nut.
(b) Using SST, remove the tie rod assy LH from the steering
knuckle.
SST 09628-6201 1
8. DISCONNECT TIE ROD ASSY RH
SST 09628-6201 1
HINT:
Remove the RH side by the same procedures with LH side.
9. DISCONNECT STEERING INTERMEDIATE SHAFT
SUB-ASSY
(a) Loosen the bolt and remove the clamp from the steering
column hole cover No.1.
(b) Disconnect the steering column hole cover No.2 from the
steering column hole cover No.1.
(c) Loosen the bolt.
Page 744 of 969
F41595
Matchmarks
F41524
F41523
F41578SST
51-22
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
2597 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(d) Place matchmarks on the steering intermediate shaft
sub-assy and rack & pinion power steering gear assy.
(e) Remove the bolt and disconnect the steering intermedi-
ate shaft sub-assy.
10. DISCONNECT FRONT STABILIZER LINK ASSY LH
(a) Remove the nut and disconnect the front stabilizer link
assy LH from the shock absorber assy front LH.
HINT:
If the ball joint turns together with the nut, use a hexagon
wrench (6 mm) to hold the stud.
11. DISCONNECT FRONT STABILIZER LINK ASSY RH
HINT:
Remove the RH side by the same procedures with LH side.
12. REMOVE FRONT STABILIZER BRACKET NO.1 LH
(a) Remove the 2 bolts and disconnect the front stabilizer
bracket No.1 LH.
13. REMOVE FRONT STABILIZER BRACKET NO.1 RH
HINT:
Remove the RH side by the same procedures with LH side.
14. DISCONNECT PRESSURE FEED TUBE ASSY
(a) Using SST, disconnect the return tube assy from the rack
& pinion power steering gear assy.
SST 09023-12701
Page 745 of 969
F42897SST
F41602
F41568
F41496
- POWER STEERINGRACK & PINION POWER STEERING GEAR ASSY
51-23
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2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(b) Using SST, disconnect the pressure feed tube assy from
the rack & pinion power steering gear assy.
SST 09023-12701
(c) Remove the nut and disconnect the return tube assy
clamp.
15. REMOVE RACK & PINION POWER STEERING GEAR
ASSY
(a) Remove the bolt and disconnect the tube clamp.
(b) Remove the 2 bolts, 2 nuts and rack & pinion power steer-
ing gear assy.
16. REMOVE POWER STEERING RACK HOUSING HEAT INSULATOR
(a) Remove the power steering rack housing heat insulator.
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.