Step 2 Vol 11 Steering System [PDF]

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Vol. 11



Steering System TEAM



Step



2



Pub. No. TTM211EN



TABLE OF CONTENTS Page



Page POWER STEERING



STEERING SYSTEM



Descri pt ion .•....•..••...••..••...•...•••..••...................



1



STEERING COLUMN



Des cript ion



3



Steering Column Impact-absorbi ng Mechanism



Tilt Steering Mechanism



Descri pt ion ......................•....•.......••••.•.....•......



53



Vane Pump .....................................................



57



Gear Housing Descri pt ion ..........................................•..•..•



63



4



Rotary Valve Type



64



6



Spool Valve Type



69



Flapper Valve Type



75



Telescopic Mechanism ••.••.•.••..•.•..................



12



Steering l ock Mechan ism



14



MANUAL STEERING



TROUBLESHOOTING (for pow er steeri ng) ••...



79



Description .•.•.•••••.•....••..•••...•..••••.••••.•....••.•••...



79



Trou bleshooti ng



79



Description



19



Rack-and-Pi nion Ty pe



20



~ ON-V EHICLE INSPECTION



Recir cu lati ng-Ball Ty pe



22



lfor pow er steering) •...•.••.............................•....



81



Checking Drive Belt Tension .........•..••••.••....•



82



STEERING LINKAGE Ty pes of Linkage



24



Fluid Level Check ................................•••..•.....



83



Lin kag e Components ......••..••.....•........••.•••..••



25



Check ing Idle -up .••...•.•...................................



83



Rep lacement of Pow er Steering Fluid



84



29



Bleeding of Pow er Steering System



85



Description



29



Flu id Pressure Check •.••••..•...•••.••••..•....•..••••.••



85



Trou bleshooti ng



29



~ POWER STEERING PUMP OVERHAUL ••...



87



m OUBLESHOOTING lf or manual steering)



~ REMOVAL AND IN STALLATION OF



Disassembly of Powe r Stee ring Pump



88



37



Inspect ion of Power Stee ring Pum p



91



Mai n Points of Remova l and Install ati on .....



38



Assembly of Pow er Steeri ng Pump ........•..••



93



Disassem bly and Assem bl y of Id ler A rm Bracket ..••..•••........••..•.....•..•.•......................



40



Disconnection and Connectio n of Drag Lin k ................................•••.•.••............•...•••••



42



STEERING LINKAGE



r.i



POWER STEERING GEAR HOUSING



OVERHAUL rroyot a type & Kayo type) ••........



~ RACK & PINION STEERING GEAR



Disassemb ly of Steering Gear Hou sing



97 99



Inspect io n and Rep lacement of Gear Hou sing Compon ents ................••••.•••....... 103



OVERHA UL .........................................................



43



Disassem bly of Gear Housing .•••.••.......•••.••..



44



Inspection and Replacem ent of Gear Hou sing Component s ...•..•••..•...................



46



Descri pti on



115



Assem bly of Gear Ho usin g •...•................•.....



48



Progressive Pow er Steering



116



Assembly of Stee rin g Gear Hou sing



108



PROGRESS IVE POWER STEERING IPPSI



Hyd rau lic React ion Type Prog res sive Pow er St eering



118



STEERING SYSTEM -



Description



STEERING SYSTEM DESCRIPTION The purpose of the st eering syste m is to allow the



Th e ste ering system confi gurat ion depends on ve-



dri ver to cont ro l the direct ion of t he vehicle by



hi cle de sign (t he d rive train and suspension sys-



turni ng the f ront whee ls.



tems used , w hethe r it is a passenger car o r a co m-



Thi s is done by means of a steering w heel. a ste ering co lum n w hich transmits the rotation of th e steerin g w heel to the steering gears, th e st eering gears



m erc ia l vehicle, etc.l . At present, the rack-and-pinion type and the reci rcul ating-b all types are in use. The se are sh own below .



wh ich increase the rotat ional force of t he stee ring wheel in order to t ran sm it g reater torque t o the steering linkage , and th e st eering linkage w hich transmits the steering gear m ovem ent to t he f ron t w heels.



Steering wheel



Steering column



Steering col umn



Steering gear



RACK-AND-PINION TYPE STEERING



Steering linkage



RECIRCULATING-BALL TYPE STEERING



STEERING SYSTEM - Descr iption REQUIREM ENTS OF STEERING SYSTEM



The stee ring syste m plays, together w ith th e s uspe ns ion system. an im po rta nt role in ens uring easy. co mfo rta ble d riving all the way fro m the low spee d range to the high s peed ranges. The drive tra in transmits the powe r from the e ngine to the d riving wheels to m ove the ca r forwa rd; th e steeri ng svstem steers the car in the desi red direction; and th e brake system ensures pos itive, stable slowi ng and stopping .



(j) EXCELLENT M A NEUVERAB ILITY When the ca r is co rnering on a narrow . twisting road. the steering system must be a ble to t urn th e front w heels sharply ye t easily an d smoothly.



®



PROPER STEERING EFFORT



If nothing is do ne to prevent it, steering effo rt will be grea ter wh en the car is stopped and will de--



crease as the s peed of the ca r increases. Therefo re, in order to obta in easie r s teering an d better feel of the roa d, the steeri ng s hould be ma de lig hter at low s peeds and heavier at high s peeds .



@



SMOOTH RECOVERY



While the ca r is turn ing. the driver mu st ho ld the stee ring wheel firm ly. Afte r th e turn is completed, however, recovery - that is, the return of the whee ls to the straig ht-a head pos itio n - sho u ld occur smoothly as the driver rela xes the fo rce w it h which he is turn ing the s tee ring whe el.



@ MI NIM UM TRANSM ISSION OF SHOCK FROM ROAD SURFACE



loss of steering whee l control a nd trans m iss ion of kickback due to ro ad su rlace roug hn es s mu st not occur.



2



STEERING SYSTEM - Descripti on



STEERING COLUMN DESCRIPTION The stee ring col um n consists of the main steering



The bottom end of the steering main shaft is con-



shaft which transmits the steering wheel rotatio n t o



nected to the steering gear, genera lly by way of a



the stee ri ng gear, and the column t ube w hic h fi xes



flexible jo int or unive rsal jo int to m inimize the trans-



the steering m ain shaft to the body . The top end of



mission of road shock from the steering gear to the



the steering main shaft is ta pered and serrated, and



steering wheel.



the steering wheel is fi tted to it by a nut.



In addition to the impact-absorbing me chanism,



The steeri ng colum n incorporates a impact absorb-



the steering ma in shaft on some veh icles may also



ing-mechanism that absorbs the thrust force that



contain a nu mber of steeri ng contro l systems: for



would otherwise be applied to the d river at the time



example, the steering lock mechanism which locks



of a collision. The steering col um n is fitted t o the



the main shaft completely; the tilt steering mecha-



body via a breakaway type column bracket so that



nism, which allows t he driver to adjust the vertica l



the steering co lum n can easily collapse in a crash .



position of the steering wheel; the te lescopic steering system, which let s the driver change the length of the steering shaft freely to obtain an optimal



I\



Steering wheel



driving pos it ion; etc .



Breakaway bracket Body



Steerin g main shaft (upper)



Tilt lever



Colum n tu be Stee ring main shaft (lower)



NON-TILT STEERIN G



OHP 1



TILT STEERING



OHP 1



3



STEERING COLUMN -



St eer ing Col umn Im pact- abso rbing Mechanism



STEERING COLUMN IMPACTABSORBING MECHANISM Whe n a ca r is invo lved in a collision, this m echa-



The steeri ng co lum n bre akaway bracket is bo lte d to



ni sm helps prevent t he ma in shaft fro m injuri ng



the instrument panel br ace v ia two capsules. Th e



t he drive r in t w o ways: by t he br eak ing at t he t ime



caps ules are inst alled ont o the col um n upper bracket



of t he co llisio n (prima ry shock); and by reduci ng



wit h four plast ic pins.



t he sec ondary sho ck im posed upon t he dr iv er's body when it hits the st eering w heel due t o inert ia .



Capsule



I



Energ y-absorbin g stee ring col um ns are classifie d int o t he fo ll owing types: • Bend ing bracket type • Ball ty pe • Sealed-in pul v erize d silicon -rubber type • M esh t ype • Bel lows ty pe



BENDING BRACKET TYPE Steering column t ube



CONSTRUCTION Breakawav bracket



A pr ess-f ormed bend ing bracket is welded t o th e co lum n t ube and f asten ed t o th e vehicle body w ith nuts. Th e capsu le po rt ion of th e breakaw ay br acket



INSTALLATION OF BREAKAWAY BRACKET



is als o f asten ed to t he body. The stee ring ma in shaft is div ide d int o u pper



OPERATION



and low er section s, w hich are co n nect ed b y



c, >c,



OHP 15



VARIABLE GEAR RATIO TYPE



C, -c.> c, 0 , " 0, " 0 ,



Varia ble gear ratio CONSTANT GEAR RATIO TYPE



OHP 15



Cons tant gear rat io 2 .5: 1



19 .5 :1



1



TUR NING AN GLE OF



SECTOR SHAFT



Stra ight a head position CONSTANT V5. VARIABLE GEAR RATIO



OHP 15



23



STEERING LIN KAGE -



Ty pes of linkage



STEERING LINKAGE A stee ring linkage is a com binatio n of the rods and arms t hat transm it th e m ovem ent of th e stee ring



Tie rod end



gea r to th e left and right f ro nt w hee ls. Th e stee ring linkage m ust accura tely transm it th e m ovem ent of t he st eering whee l t o th e front w hee ls as t hey move up and down w hile t he car is in mot ion . There are various linkage arra ngeme nts and j oi nt const ruct io ns des ig ned to do this. Th e app ro pria teness of t he design great ly affects t he stability of dri v ing .



~



Steering gear Rack end



f:8 .-.



Steering knuckle



Tie rod end OHP 16



TYPES OF LINKAGE 1. STEERING LINKAGE FOR INOEPENDENT FRONT SUSPENSION {IFSJ



2. STEERING LINKAGE FOR RIGID-AXLE FRONT SUSPENSION (RFS)



Since t he left and rig ht front w hee ls move up and



The steering linkage f or the rigid-axle f ront suspen-



down independ ently of each ot her, t he distance



sia n co nsists of t he pitm an arm, drag link, knuckle



between the knu ckl e arms v aries. This mea ns that,



arm s, ti e rod and ti e rod ends . In the rigid -axl e type



if on e ti e rod is use d to co nnect both w heels, im-



steeri ng lin kage. vertical m ove m ent of the car body



pro per toe-in w ill result w hen the w hee ls move up



do es not cause the t read (t he dista nce betwee n the



and down. Th e steering lin kage f o r the ind epen-



rig ht and [eft w hee ls) t o change, so th e rig ht and



dent fron t suspensio n t herefore uses two tie rods.



left knuck le arms can be co nnected by a sing le t ie



Th ese are con nected by a relay rod (th e rack itself



ro d.



act s as the re lay rod in the case of t he rack-an d-



Since t he stee ring gea r is f ixe d to t he f ra me. the



pi nio n type). A n adjusti ng tu be f or t oe-in adjust-



drag link, w hich co nnects it to t he knu ckle arm , is



ment is provided between th e ti e rod and t ie rod



provided with a ball j oint at each end to all ow it to



end .



move up and dow n w ith th e movements of the suspe nsio n (leaf) spri ngs.



Steering gear Steering gear



Knuckle arm



Idler arm



Tie rod end Tie rod (adjusting tube) Relay rod



Pitman arm



Tie rod OHP 16



24



Tie rod end



OHP 16



STEERING UNKAGE - linkage Com ponents



LINKAGE COMPONENTS 1. PITMAN ARM



3. TIE ROD



The pit man arm t ransmits the movement of the



The tie rod end screws into the rack end on rack-



steering gear t o the relay rod or drag link. The large



and-pinion steering , or into the adjusting tu be on



end of the arm is taper-spli ned to the secto r shaft of



reci rculating-ball steering, so that th e distan ce be-



the steering gear and f ixed by a nu t. The small end



tween joints can be adj usted.



is con nected to the relay rod or drag li nk by a ball joi nt.



Tie rod end



Rack end



Pitman arm_ _ ~~~



Tie rod end



Tie rod (adjusting tubel



Tie rod



4. TIE ROD END 2. RELAY ROD Tie rod ends are mo unted on the ends of tie rods to The relay ro d is linked to the pitma n arm and the



connect the tie rods with the knuckle arms , relay



left and right tie rods. It t ransmi ts th e motions of



rod etc. They fo rm a ball joint as shown in the



the pitm an arm to the tie rods. It is also linked t o the



il lust rati on below .



idler arm .



Ball stud



-e



Oust cover Ball seat



Idler arm



\ %:;



'"



Tie rod



Relay rod



Since the ti e rod end used in passenge r cars are usually of the lubricat ion-free ty pe, th e ball seat Tie rod



materi al used must be slow t o w ear, the sealing perform ance of the dust cove r mu st be bett er tha n usual, and non-deterior ating g rease mu st be used.



25



STEERING LINKAGE A ti e rod end incorporati ng a spring f or preload ing



and wear compensat io n as shown below is also used .



Li nkage Com ponents



6. STEERING KNUCKLE Th e ste ering knuckles support th e load applie d t o t he f ron t w heels, and also f unct ion as t he rot ati onal axes of the w hee ls. The ste ering knuck les pi v ot arou nd t he ball j oint s or king pins of t he suspen-



Ball stud



sion arm s to ste er the front wheels.



Ball joint



Dust cover



Ball sea t Spring



Ball joint



5. KNUCKLE ARMS The knuckle arms t ran sm it th e movement of th e t ie rods o r d rag link t o the f ron t whee ls v ia t he st eering The co nstructi on of t he stee ri ng knuckle and ax le



knuckles.



hub di ffers as shown in t he f ig ures be lows depending on w het he r t he car is a f ro nt-, rear -, or f ourw heel-d rive ve hi cle.



Ball joint



Axle hub Knuckle arm



Ball j oint



FR TYP E VEH ICLES



26



STEERING UNKAGE -



Linkage Com po nents



7. IDLER ARM The pivot of the idler arm is installed to the body, and the other end is co nnected to the relay rod by a sw ive l joint . Th is arm supports one end of the relay rod, and rest ricts the motion of t he relay rod to the prope r range . The idler arm bearing is of eit her the slid ing or the t orsional type. The t orsional bearing type idler arm Axle hub



uses a rubber bushi ng between the shaft and support for easy steering wheel recovery. At present, the slidi ng bear ing type id ler arm is most freq uently used due to its reduced rotational friction .



Ball joint



o



o



FF/FR TYPE VEHICLE



(Angular ball bearing ty pe)



King pin SUDING BEARING TYPE



Ax le hub



o



Steering kn uckle



o



-"c;::;,~e=;:::v~ Rubber bushing .. ,-e .- .. ~.



- ..



'-



KING PIN TYPE 4WD VEHICLES



TORSIONAL BUSHI NG TYPE



27



STEERING LINKAGE - Linkage Components



8. DRAG LINK The drag link connects t he pitm an arm to t he knuckle arm , act ing as a link w hi ch t ransm its the fo rw ard and backwa rd , and left and rig ht movements of t he pitman arm . Steering gear



Knuckl e arm



! Pitman arm Tie rod end



Pitma n arm Drag link



Screw plug



Clearance Ball seat -~ Screw plug



,



cotter om



~··~i;i~~b"~~.c



~~:~~~~J~~~ .cott., pin



Spri ng seat Spring Clearance B II Spring a seat Spring seat



Knuckle arm



9. STEERING DAMPER The steering dam per is a shock abs orbe r placed between the steering linkage and fram e t o damp the shock and v ibrat ion t ran smitted f rom the w heels to t he st eering w heel.



Steerin g damp er Relay rod



'8



TROUBLESHOOTING -



Description , Troubleshooti ng



TROUBLESHOOTING (For Manual Steerin g) DESCRIPT ION Wh en checking the steeri ng syste m, bear in m ind



Therefor e, befo re decid ing that a problem lies in



that there is a close connec tion between it and the



the steering syste m, consider and check out all



front wheels, suspensio n, ax les and frame. For th is



other possibl e causes - t his will save a lot of tim e



reason , problem s that m ay appear t o the driver as



and effort.



orig inati ng in th e steeri ng syste m, may in fact be due to other causes, such as problems in th e suspension, etc.



TROUBLESHO OTIN G EXCESSIV E STEERING WH EEL FREEPLAY



Since th ere are many joints in the steering system,



system parts and worn joints may cause the car to



a sli ght play is to be expected . However, an exces-



wa nde r or pull to o ne side, and will cause v ib ration



sive play resu lting from loosely installed steering



and abno rma l ti re we ar.



I (j)



LOOSE



CHECK STEERING COLUM N



REPA IR



I



REPA IR OR REPLACE



I



REPAIR OR REPLACE



I



I @ CHECK STEERINGWHEEL FREEPLAy-j



H



CHECK M A IN SHAFT & J OINTS



H ® CHECK LINKAGE



H



LOOSE OR WO RN LOOSE OR WOR N



CHECK ST EERING GEAR HOUSING OR GEA R BOX INSTAL LATI ON



I I



LOOSE



CHECK ST EERING GEAR BAC KLASH (fo r recircul at ing -ball type)



I I



EXCESSIVE



I @ CHECK W HEEL BEA RINGS



LOOSE



I



WORN



CHECK BALL JOINTS OR KINGPIN



I



I



TIGHTEN



I A DJ UST, REPAIR OR . I REPLACE



I I



ADJUST



I



REPLACE



I



-NOTES -



-



f



:



JJ .



O·'; ng " C @,.J Snap ring



(Ii ~_ __ __ _ _ _ _ _ _ _________



J..,/ ~ \) • Oil seal 440 (32 43) ~ , Pulley (for 2E, 4A-F Engine)



~ < ()



~



~~



Rear side plate



-, Cam ri ng Vane _ • c -nng Front side plate Shaft



I kg-cm (ft·lb, Nom) I: Specified torqu e • Non-re usable part



87



POWER STEERING -



Pow er Steering Pump Ov erha ul



DISASSEMBLY OF POWER STEERING PUMP 1.



MOUNT POWER STEERING PUMP IN VISE



~ NOTICE Do not ti ghten the vi se too t ight .



2.



- - -)



(For 2E, 4A-F & 4A-FE Engin es) REMOVE DRIVE PULLEY (a)



Usi ng th e SST to hold t he pulley, rem ove th e pu lley set nut.



SST 09616-30020 (fo r 2E &