Mazda Trucks 1994-1998 Repair Guide

Manual Steering Gear

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ADJUSTMENTS



See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Measuring the steering gear preload

Preload and Meshload
INSPECTION
  1. Raise and support the front of the vehicle on jackstands.
  2.  
  3. Disconnect the pitman arm at the ball stud.
  4.  
  5. Lubricate the wormshaft seal with a drop of automatic transmission fluid.
  6.  
  7. Remove the horn pad from the steering wheel.
  8.  
  9. Turn the steering wheel slowly to one stop.
  10.  
  11. Using an inch-pound torque wrench on the steering wheel nut, check the amount of torque needed to rotate the steering wheel through a 1 1 / 2 turn cycle. The preload should be 2-6 inch lbs. If correct, proceed with the rest of the steps. If not perform preload and mesh adjustment.
  12.  
  13. Rotate the steering wheel from stop-to-stop, counting the total number of turns. Using that figure, center the steering wheel ( 1 / 2 the total turns).
  14.  
  15. Using the inch-pound torque wrench, rotate the steering wheel 90° to either side of center, noting the highest torque reading over center. The meshload should be 4-10 inch lbs. (0.5-1 Nm), or at least 2 inch lbs. more than the preload figure.
  16.  

ADJUSTMENT
  1. Remove the steering gear from the vehicle.
  2.  
  3. Torque the sector cover bolts on the gear to 32-40 ft. lbs.
  4.  
  5. Loosen the preload adjuster nut and tighten the worm bearing adjuster nut until all end-play has been removed. Lubricate the wormshaft seal with a few drops of automatic transmission fluid.
  6.  
  7. Using an 11 / 16 in., 12-point socket and an inch lbs. torque wrench, carefully turn the wormshaft all the way to the right.
  8.  
  9. Turn the shaft back to the left and measure the torque over a 1 1 / 2 turn cycle. This is the preload reading.
  10.  
  11. Tighten or loosen the adjuster nut to bring the preload into range: 5-6 inch lbs. (0.5-1 Nm).
  12.  
  13. Hold the adjuster nut while torqueing the locknut to 166-187 ft. lbs. (225-252 Nm).
  14.  
  15. Rotate the wormshaft stop-to-stop counting the total number of turns and center the shaft ( 1 / 2 the total turns).
  16.  
  17. Using the torque wrench and socket, measure the torque required to turn the shaft 90° to either side of center.
  18.  
  19. Turn the sector shaft adjusting screw as needed to bring the meshload torque within the 9-11 inch lbs. range, or at least 4 inch lbs. higher than the preload torque.
  20.  
  21. Hold the adjusting screw while tightening the locknut to 14-25 ft. lbs. (19-34 Nm).
  22.  
  23. Install the gear.
  24.  

REMOVAL & INSTALLATION



See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: View of the 1994-97 B Series Pick-up manual steering gear and related parts

  1. Raise and safely support the vehicle using jackstands. Disengage the flex coupling shield from the steering gear input shaft shield and slide it up the intermediate shaft.
  2.  
  3. Remove the bolt that retains the flex coupling to the steering gear.
  4.  
  5. Remove the steering gear input shaft shield.
  6.  
  7. Remove the nut and washer that secures the pitman arm to the sector shaft. Remove the pitman arm using pitman arm puller tool, T64P-3590-F or equivalent. Do not hammer on the end of the puller as this can damage the steering gear.
  8.  
  9. Remove the bolts and washers that attach the steering gear to the side rail. Remove the gear.
  10.  

To install:
  1. Rotate the gear input shaft (wormshaft) from stop to stop, counting the total number of turns. Then turn back exactly half-way, placing the gear on center.
  2.  
  3. Slide the steering gear input shaft shield on the steering gear input shaft.
  4.  
  5. Position the flex coupling on the steering gear input shaft. Ensure that the flat on the gear input shaft is facing straight up and aligns with the flat on the flex coupling. Install the steering gear to side rail with bolts and washers. Torque the bolts to 66 ft. lbs. (89 Nm).
  6.  
  7. Place the pitman arm on the sector shaft and install the attaching washer and nut. Align the 2 blocked teeth on the Pitman arm with 4 missing teeth on the steering gear sector shaft. Tighten the nut to 170-228 ft. lbs. (230-310 Nm).
  8.  
  9. Install the flex coupling to steering gear input shaft attaching bolt and tighten to 50-62 ft. lbs. (68-84 Nm).
  10.  
  11. Snap the flex coupling shield to the steering gear input shield.
  12.  
  13. Check the system to ensure equal turns from center to each lock position.
  14.  

 
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