Service Manual2005 KALOS MANUAL STEERING GEAR

SECTION 6D

MANUAL STEERING GEAR

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

General Specifications

Application			Description
Type			Rack & Pinion
Overall Gear Ratio			26.4:1
Steering Angle	(155)Tire	Inside	39.5°
	.	Outside	33°
	(175)Tire	Inside	39.5°
	.	Outside	33°
Grease	Rack		Grease No.2 Li
Grease	Ball Joint		Nerita 0460 & Retinax or Crown #2

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
Adjuster Plug Locknut	70	52	-
Coolant Surge Tank Attaching Nuts	4	-	35
Coupling Flange Pinch Bolt	22	16	-
Inner Tie Rod Bolts	90	66	-
Outer Tie Rod Hex Nut	60	44	-
Pinion Preload	0.7 to 1.5	-	6 to 13
Steering Gear Retaining Bracket Nuts or Bolts	38	28	-
Steering Gear Retaining Bracket Studs	20	15	-

SPECIAL TOOLS

Special Tools Table

	KM-J-26610 Installer
	KM-472 Wrench

KM-507-B

Ball Joint Remover

DIAGNOSIS

Manual Rack and Pinion Steering Gear

Excessive Play or Looseness in the Steering System

Checks	Action
Check the steering gear adjustment.	Perform straight-ahead check.
Check the wheel bearing for wear or damage.	Replace the wheel bearing.
Check the outer tie rods for improper installation.	Tighten the tie rods.

Rattling Noise in the Steering Gear

Checks	Action
Check the steering gear for improper and insufficient lubrication.	Lubricate the rack assembly. Lubricate the pinion assembly.
Check the steering gear mounting for improper installation.	Tighten the steering gear mounting bolts and the nuts.
Check the outer tie rods for improper installation.	Tighten the tie rods.

Straight-Ahead check

After all the necessary operations on the steering gear are completed, check the exact straight-ahead position of the steering in each case.

With the vehicle on the floor, place the steering wheel in the straight-ahead position. Mark the centerline of both tires on the floor. Turn the steering wheel all the way to the right and mark the new centerline of both tires on the floor.

Straight Ahead Check Table

Step	Action	Value(s)	Yes	No
1	Place the steering wheel in the straight-ahead position Is the wheel in the correct position?	-	Go to Step 2	-
2	Is the steering coupling flange pinch bolt lying horizontally?	-	Go to Step 3	Go to Step 4
3	Is the steering wheel off center by more than 5 degrees?	-	Go to Step 5	Go to Step 6
4	The pinion is displaced on the rack. The steering pinion position must be corrected. Is the repair complete?	-	Go to Step 2	-
5	Remove steering wheel and center on the spindle splines. Is the repair complete?	-	Go to Step 3	-
6	Turn the steering wheel all the way to the right. Measure the inner and the outer angles of the tire centerline compared to the straight-ahead centerline. Do the angles match the value specified?	Inner angle: 39°5' ± 1°30' Outer angle: 34° ± 1°30'	System OK	Go to Step 7
7	The rack assembly was not assembled correctly. Repair as needed. Is the repair complete?	-	Go to Step 6	-

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

Rack and Pinion assembly

Tools Required

KM-507-B Ball Joint Remover

Removal Procedure

Disconnect the negative battery cable.
Position the tires straight ahead by turning the steering wheel.
Remove the Interm Shaft. Refer to Section 6E, Steering Wheel And Column.
Remove the Front Tires.

Remove the outer tie rod hex nuts. Refer to "Outer Tie Rod" in this section.

Remove the ball joint hex nuts and disconnect the stabilizer shaft from the knuckle by removing the stabilizer shaft link assembly.Refer to Section 2C, Front Suspension.

Remove the cross member by removing the nuts and bolts to the underbody.

Remove the Rack and Pinion assembly by disconnecting the steering gear retaining bracket nuts.

Installation Procedure

Install the Rack and Pinion assembly by connecting the steering gear retaining bracket nuts.

Tighten

Tighten the steering gear retaining bracket nuts to 50 N•m(37 lb-ft).

Install the cross member by tightening the nuts and bolts to the underbody.

Tighten

Tighten the cross member by tightening the nuts and bolts to the underbody to 150 N•m (111 lb-ft).

Install the ball joint hex nuts and connect the stabilizer shaft to the knuckle by tightening the the bolt with stabilizer shaft link assembly. Refer to Section 2C, Front Suspension.

Tighten

Tighten the ball joint hex nuts to knuckle to 45 N•m(33 lb-ft). Tighten the bolts of stabilizer shaft to the knuckle to 45 N•m(33 lb-ft).

Install the outer tie rod hex nuts.

Tighten

Tighten the outer tie rod hex nuts to 45 N•m (33 lb-ft).

Install the Front Tires. Refer to Section 2E, Tires and Wheels.

Install the Interm Shaft. Refer to Section 6E, Steering Wheel And Column.
Install the steering wheel and column.
Connect the negative battery cable.

Important : After all the operations with the steering gear, be sure to check the exact straight-ahead position of the steering in each case.Refer to "Straight-ahead check" in this section.

Outer Tie Rod

Tools Required

KM-507-B Ball Joint Remover

Removal Procedure

Remove the outer tie rod hex nut and disconnect the outer tie rod from the steering knuckle using the special tool KM-507-B.

Loose the tie rod lock nuts and remove the outer tie rod.

Important : Before loose the tie rod lock nut, mark the position of the lock nut for easy alignment after installation procedure.

Installation Procedure

Install the outer tie rod by tightening the lock nuts to 54 N•m(40 lb-ft).

Install the outer tie rod by tightening the hex nut to 45 N•m(33 lb-ft).

Inner Tie Rod

Removal/Installation Procedure

Refer to the unit repair of manual steering gear in this section.

Rack Bearing Preload On-Vehicle Adjustment

Adjustment Procedure

Make the rack bearing adjustment with the front wheel raised and the steering wheel centered. Be sure to check the returnability of the steering wheel to center after the adjustment.

Loosen the locknut and turn the adjuster plug clockwise until a torque of 10 N•m (88 lb-in) is obtained.
Back the adjuster plug off by 55 to 65 degrees. Check the pinion preloaded torque is within the range 0.9 to 1.7 N•m (8 to 15 lb-in).
Tighten the adjuster plug locknut while holding the adjuster plug stationary.

Tighten

Tighten the adjuster plug locknut to 70 N•m (52 lb-ft).

Straight-Ahead check

After all the necessary operations on the steering gear are completed, check the exact straight-ahead position of the steering in each case.

Straight-Ahead Check Table

Step	Action	Value(s)	Yes	No
1	Place the steering wheel in the straight-ahead position. Is the wheel in the correct position?	-	Go to Step 2	-
2	Is the steering coupling flange pinch bolt lying horizontally?	-	Go to Step 3	Go to Step 4
3	Is the steering wheel off center by more than 5 degrees?	-	Go to Step 5	Go to Step 6
4	The pinion is displaced on the rack. The steering pinion position must be corrected. Is the repair complete?	-	Go to Step 2	-
5	Remove steering wheel and center on the spindle splines. Is the repair complete?	-	Go to Step 3	-
6	Turn the steering wheel all the way to the right. Measure the inner and the outer angles of the tire centerline compared to the straight-ahead centerline. Do the angles match the value specified?	Inner angle: 39°5' ± 1°30' Outer angle: 34° ± 1°30'	System OK	Go to Step 7
7	The rack assembly was not assembled correctly. Repair, as needed. Is the repair complete?	-	Go to Step 6	-

UNIT REPAIR

The unit repair of this section is similar to the unit repair of power Steering gear. Refer to Section 6C, Power Steering Gear.

GENERAL DESCRIPTION AND SYSTEM OPERATION

Manual Rack and Pinion

The manual rack and pinion steering system consists of two main components: the rack and the pinion. The motion of the pinion is transferred through the pinion teeth that mesh with the teeth on the rack, which moves the rack. The force is then transmitted through the arms on the struts, which turn the wheels.