MAZDA 626 1987 Workshop Manual

4-WHEEL STEERING GEAR AND LINKAGE 1 0
76G10X-035
1. Temporarily install the front bracket.
2. Install the rear bracket, and then tighten at the
specified torque.
Tightening torque:
22—30 Nm (2.2—3.1 m-kg, 5.1—7.2 ft-lb)
3. Tighten the front bracket bolt.
Tightening torque:
22—30 Nm (2.2—3.1 m-kg, 5.1—7.2 ft-lb)
Caution
The shaft should be installed by two or more
persons, taking care not to bend the joint part.
4. Connect the joint of the front steering gear side,
and then tighten the bolt.
5. Connect the joint of the rear steering gear side, and
then tighten the bolt.
86U10X-320
Caution
Check to be sure that the front and rear brack-
ets do not contact the oil seal.
86U10X-321
Attach a new wire and clamp, and as shown in the
illustration be sure that protrusion is within 5mm
(0.2 in).
Install the cover.
86U10X-322
10—43

1 0 4-WHEEL STEERING GEAR AND LINKAGE
INSPECTION
Front Steering Gear and Linkage
1. Check the following and replace the front steering
gear assembly if necessary.
(a) Damaged or cracked case
(b) Bent linkage
86U10X-079
2. Check the following and replace any faulty parts.
(a) Clogged, bent, or pinched pipes
(b) Faulty oil pressure switch
(c) Damaged mounting bracket and mounting
rubber
(d) Cracked, damaged, or deteriorated boots
86U10X-080
Available spare parts
86U10X-081
1. Tie-rod end 7. Oil pressure switch
2. Tie-rod end boot 8. O-ring
3. Nut 9. Mounting bracket
4. Boot 10. Mounting rubber
5. Boot band (large) 11. Oil pipe
6. Boot band (small) 12. Steering gear assembly
10—44

4-WHEEL STEERING GEAR AND LINKAGE 1 0
Steering Angle Transfer Shaft
Check the following and replace the shaft assembly
if necessary
1. Shaft
(a) Cracked, damaged, or deteriorated boots
(b) Stuck carrier bearing
(c) Bending
(d) Damaged mounting brackets
86U10X-082
2. Universal joint
Looseness or damage
3. Rear boot
Crackes, damage, or deterioration
86U10X-083
Available spare parts
86U10X-084
1. Shaft 3. Rear boot 5. Clip
2. Universal joint 4. Wire
10-45

1 0 4-WHEEL STEERING GEAR AND LINKAGE
86U10X-085
Rear Steering Gear and Linkage
1. Check the following and replace the rear steering
gear assembly if necessary.
(a) Damaged or cracked case
(b) Faulty stepper motor or rear-to-front steering
ratio sensor
(c) Sticking bearings
(d) Oil leakage
Note
There is no fluid in a new replacement rear
steering gear assembly, add fluid to the spe-
cified level. (Refer to 10—12.)
2. Check and tighten bolts and nuts, if necessary.
3. Check the following and replace any faulty parts.
(a) Cracked, damaged, or deteriorated rear stee-
ring gear boots and bands
(b) Cracked or damaged oil pan
(c) Malfunctioning solenoid valve
86U10X-086
10-46

4-WHEEL STEERING GEAR AND LINKAGE 1 0
Available spare parts
86U10X-087
1. Tie-rod end 9.
2. Tie-rod end boot 10.
3. Nut 11.
4. Boot 12.
5. Boot band (wire) 13.
6. Boot band (clip) 14.
7. Oil pan 15.
8. Oil pan gasket 16.
Bolt
Oil filler bolt
Solenoid valve (Refer to 10—41)
Bolt
Oil filter set (Refer to 10—41)
Steering gear assembly
Pipe
10—47

10 MANUAL STEERING
MANUAL STEERING
DISASSEMBLY
Disassemble in the sequence shown in the figure, referring to the disassembly note for specialy marked
parts.
Note
Before disassembling, drain the gear oil and remove all external grease and dirt.
86U10X088
1. Tie-rod end
2. Nut
3. Clip
4. Boot wire
5. Boot
6. Tie-rod
7. Washer
8. Adjust cover locknut
9. Adjust cover
10. Spring
11. Friction block
12. Dish spring
13. Holder
14. Needle roller
15. Roller assembly
16. Boot support
17. Rear cover locknut
18. Rear cover and oil seal
19. Bearing
20. Pinion
21. Bearing
22. Rack
23. Gear housing
24. Mounting rubber and
bracket
25. Bushing
10—48

MANUAL STEERING 1 0
Disassembly Note
Steering gear and linkage
Secure the gear and linkage in a vise.
Caution
Insert protective material (such as copper
plates) in the jaws of the vise.
86U10X-089
Tie-rod ends
Before removing the tie-rod ends, make a mark for
proper installation.
86U10X-090
Tie-rods
Remove the tie-rods.
1. Uncrimp the washer as shown in the figure.
86U10X-091
2. Secure the rack in a vise and remove the tie-rod.
86U10X-092
10—49

10 MANUAL STEERING
Adjust cover
1. Loosen the locknut, and remove the adjust cover
with the SST.
2. Remove the spring, friction block, dish springs
holder, and needle roller assembly.
86U10X-093
Pinion
Gently grasp the serrated part of the pinion and pull
it out of the gear housing.
Caution
If the pinion is difficult to remove, gently tap
the gear housing with a plastic hammer while
pulling.
86U10X-094
Rack
Remove the rack by taking it out in the direction indi-
cated by the arrow.
Caution
Do not damage the rack bushing with the edge
of the rack gear.
86U10X-095
Bearing (lower)
Heat the housing in water to about 80°C (176°F); then
tap the end of the housing with a wooden hammer
to remove the bearing.
86U10X-096
10—50

MANUAL STEERING 1 0
86U10X-097
86U10X-098
86U10X-099
Spring Friction block
Holder
Needle roller
Roller
Bushing
Break the bushing and remove it.
Caution Be careful not to damage the gear housing.
INSPECTION
Check the following and replace any faulty parts.
1. Damaged mounting rubber or bracket
2. Cracked, worn teeth, or damaged pinion
3. Loose, noisy, or sticking bearing in gear housing
4. Cracked or damaged gear housing
5. Worn rack and housing bushing
6. Tie-rod ball-joint operation and looseness
7. Bent tie-rods or tie-rod ends
8. Cracked, worn teeth, or damaged rack
9. Runout of rack
Runout: 0.30 mm (0.012 in) max.
10. Worn or damaged roller and friction block
11. Bearing operation
12. Cracked or damaged holder
13. Weak or damaged spring
Note
If the needle bearing must be replaced, re-
place the roller assembly.
76G10X-036
10—51

10 MANUAL STEERING
14. Damaged dish springs
ASSEMBLY
Torque Specifications
86U10X-101
39—59 N-m (4.0—6.0 m-kg, 29—43 ft-lb)
49-69 N-m (5.0—7.0 m-kg, 36—51 ft-l
& S
78—98 N-m (8.0—10.0 m-kg, 58—72 ft-lb)
— 69—78 N-m (7.0—8.0 m-kg, 51—58 ft-lb)
86U10X-102
10—52