1998-2003 Suzuki Alto 4 Door Manual Rack and Pinion User Manual
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Manual Rack and Pinion for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

3B
MANUAL RACK AND PINION 3B-1
SECTION 3B
MANUAL RACK AND PINION
NOTE:
All steering gear fasteners are important attaching parts in that they could affect the performance
of vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values must be used as speci-
fied during reassembly to assure proper retention of these parts.
CONTENTS
GENERAL DESCRIPTION 3B- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS 3B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 3B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Check 3B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Rack Boot Check 3B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End Boot Check 3B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Shaft Joint Check 3B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tie Rod End Check 3B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 3B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 3B- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Rack and Pinion Assembly 3B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 3B- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3B- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 3B- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 3B-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3B-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS 3B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL 3B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION
The rack and pinion steering system consists of two main components, the rack and the pinion. When the steering
wheel is turned, the motion is transmitted to the steering shaft, lower shaft and then to the pinion.
Since the pinion teeth mesh with teeth on rack, the motion is further transferred to the rack and changed to linear
motion. The force is then transmitted through the tie rods to the steering knuckles which turn wheels.
DIAGNOSIS
DIAGNOSIS TABLE
Refer to Section 3.
STEERING WHEEL CHECK
Check steering wheel for play and rattle, holding vehicle in straight
forward condition on the ground.
Steering wheel play “a”: 0 – 30 mm (0 – 1.18 in)
If steering wheel play is not within specification, inspect as follows
and replace if found defective.
D Tie rod end ball stud for wear (ball stud should move when less
than 3.4 N·m (0.34 kg-m) torque is applied.)
D Suspension control arm joint for wear
D Steering shaft joint for wear
D Steering pinion or rack gear for wear or breakage
D Each part for looseness
STEERING RACK BOOT CHECK
Hoist vehicle.
Inspect each boot for tear. A torn boot allows entry of dust and wa-
ter which can cause wear to steering rack and pinion to produce
noise as well as rust to result in malfunction of steering system.
If even a small tear is noted, replace with new one.
Boots should be visually inspected for any damage and tear during
every periodical inspection at specified intervals and whenever ve-
hicle is hoisted for any other purpose.
3B-2 MANUAL RACK AND PINION
TIE ROD END BOOT CHECK
Inspect each boot for tear. If even a small tear is noted, replace with
new one.
STEERING SHAFT JOINT CHECK
Check shaft joint for wear, breakage and other damage and re-
place if any defect exists.
TIE ROD END CHECK
D Inspect for play in ball joint.
D Inspect for play in rack end ball joint.
In either case, if found defective, replace.
ON-VEHICLE SERVICE
NOTE:
According to necessity, apply works to right and left parts.
LUBRICATION
When inner parts of the steering gear case were disassembled,
they should be washed clean before reassembly. It is recom-
mended to use the grease as given at the right where grease ap-
plication is indicated in the text.
SUZUKI SUPER GREASE E (99000-25050) or Lithium
grease (applicable for –405C to 1305C (–405F to 2665F))
MANUAL RACK AND PINION 3B-3
3B-4 MANUAL RACK AND PINION
1. Steering lower shaft
2. Steering lower shaft lower bolt
3. Steering gear case oil seal:
Apply SUZUKI SUPER GREASE E
99000-25050 to oil seal lip.
4. Pinion bearing plug:
Fill SUZUKI SUPER GREASE E
99000-25050 to inside of pinion bearing plug.
5. O-ring
6. Steering pinion:
Apply SUZUKI SUPER GREASE E
99000-25050 to all around pinion teeth
and mating surface of pinion bearing.
7. Pinion needle bearing:
Apply SUZUKI SUPER GREASE Ex
99000-25050 to rollers of pinion needle bearing.
8. Steering rack plunger:
Apply SUZUKI SUPER GREASE E
99000-25050 to sliding part of plunger.
9. Rack plunger spring
: Tightening Torque
: Do not reuse
21. Steering rack:
Apply SUZUKI SUPER GREASE E
99000-25050 to entire surface of rack.
22. Tie-rod lock washer
23. Steering tie-rod:
Apply SUZUKI SUPER GREASE E
99000-25050 to rack end ball joint.
24. Wire
25. Boot:
Apply SUZUKI SUPER GREASE E
99000-25050 to contacting part of
tie-rod and boot.
26. Clamp
27. Tie-rod end lock nut
28. Bracket (rack side)
29. Steering rack bushing:
Apply SUZUKI SUPER GREASE
E 99000-25050 lightly to entire inner
surface of bushing.
30. Snap ring
10. Rack damper screw:
Note the installing procedure, and the
detail refer to page 3B-12.
11. Packing
12. Cap
13. Cotter pin
14. Castle nut
15. Tie-rod end
16. Steering pinion side mount
17. Bracket (Pinion side)
18. Bracket bolt
19. Steering rack housing and gear case
20. Steering rack side mount
MANUAL RACK AND PINION ASSEMBLY
REMOVAL
1) Remove steering joint cover.
2) Loosen steering lower shaft upper bolt (1), but don’t remove.
3) Remove steering lower shaft lower bolt (2) and disconnect
steering lower shaft from steering pinion shaft.
4) Hoist vehicle and remove front wheels.
5) Remove cotter pins (1) and tie rod castle nuts (2) from both
knuckles (3).
6) Disconnect tie rod ends (4) from knuckle using special tool.
Special Tool
(A): 09913-65210
7) Remove steering gear case mount bolts (1), and then remove
steering gear case mount brackets (2).
< Right side >
< Left side >
8) Remove exhaust pipe (1).
MANUAL RACK AND PINION 3B-5
9) Disconnect gear shift control shaft (1) and extension rod (2)
from transmission assembly (3).
10) Support engine with transmission jack (1) as shown.
11) Remove engine member rear bolts (2).
12) Lower engine, and then remove manual rack and pinion as-
sembly (3) as shown.
DISASSEMBLY
1) For ease of adjustment after installation, make marking (1) on
tie rod end lock nut position of tie rod thread.
2) Loosen tie rod end lock nut (2) and remove tie rod end (3).
3) Remove boot wire (1) and clamp (2).
4) Remove boot (3) from tie rod.
3B-6 MANUAL RACK AND PINION
5) Unbend bent part of tie rod lock washer (1) and remove tie rod
(2) from steering rack (3).
6) Remove rack damper screw cap (1), rack damper screw (2),
rack plunger spring (3), and rack plunger (4).
7) Remove pinion bearing plug (1) using special tool.
Special Tool
(A): 09944-26011 (43 mm socket)
8) To remove pinion assembly (1) from rack housing (2), tap rack
housing (2) using plastic hammer (3) as shown.
MANUAL RACK AND PINION 3B-7
9) Remove rack (1) from gear case (2) as shown.
CAUTION:
D Inside of steering rack bushing is coated with spe-
cial coating. As it is damageable, be very careful
not to cause damage to it when removing rack
from steering gear case.
D Do not use a wire brush when cleaning.
10) Pull out pinion needle bearing (1) from gear case using special
tools.
Special Tool
(A): 09921-20200
(B): 09930-30104
11) Remove snap ring (1).
12) Pull out rack bushing (2) from rack housing (3) using special
tool.
Special Tool
(A): 09944-48210
CAUTION:
When removing the rack bushing, be careful not to
pull out the bushing by holding the gear case in a
vise. Or the housing (pipe) may come off the gear
case.
For this work, be sure to use the specified special
tool.
3B-8 MANUAL RACK AND PINION
13) Remove gear case oil seal (1) using special tool.
Special Tool
(A): 09913-50121
14) Remove gear case O-ring (2).
INSPECTION
Rack Plunger
D Inspect rack plunger (1) for wear or damage.
D Inspect rack plunger spring (2) for deterioration.
If found defective, replace.
Steering Pinion
D Inspect teeth surface of steering pinion (1) for wear or damage.
D Inspect oil seal (2) for damage.
D Inspect gear case O-ring (3) for damage.
If found defective, replace.
Steering Pinion Bearing
Check rotation condition of bearing and inspect for wear.
If found defective, replace.
Steering Rack
Inspect for deflection, teeth wear damage, rack surface wear or
damage.
Limit of rack deflection: 0.35 mm (0.014 in)
If deflection exceeds limit, replace rack.
MANUAL RACK AND PINION 3B-9
Steering Rack Bushing
Inspect rack bushing for wear or damage.
If found defective, replace.
REASSEMBLY
Install in reverse order of disassembly, noting the following points.
D Install pinion bearing oil seal to pinion bearing plug (1) using spe-
cial tool.
Special Tool
(A): 09925-98210
D Apply grease to oil seal lip.
Grease: 99000-25050
D Apply grease lightly to entire inner surface of bushing (1).
Grease: 99000-25050
D Press-fit bushing as far into rack housing (2) as shown by using
special tool.
Special Tool
(A): 09925-98210
Distance “a”: 2.0 – 3.0 mm (0.08 – 0.12 in.)
D Install snap ring (3).
3B-10 MANUAL RACK AND PINION
D Apply grease to rollers of pinion needle bearing (1).
Grease: 99000-25050
D Press-fit pinion needle bearing (1) into gear case (2) using spe-
cial tool.
After press-fitting, make sure that bearing rollers are installed
properly.
Special Tool
(A): 09943-88211
D Apply grease to entire teeth surface of steering rack (1) and its
periphery.
“A”: Grease 99000-25050
D Slide steering rack (1) into steering gear case (2) in the direction
as shown.
CAUTION:
D Inside of steering rack bushing is coated with spe-
cial coating. As it is damageable, be very careful not
to cause damage to it when inserting rack into steer-
ing gear case.
D Do not use a wire brush when cleaning.
D Apply grease to all around pinion teeth (1), pinion bearing (2)
and gear case oil seal lip (3) as shown.
“A”: Grease 99000-25050
D Fill inside (4) of pinion bearing plug (5) with grease.
“A”: Grease 99000-25050
D Fit gear case O-ring (6) in groove of pinion bearing plug.
D Install pinion assembly (1) and tighten pinion bearing plug (2) to
specified torque.
Special Tool (43 mm socket)
(A): 09944-26011
Tightening Torque
(a): 95 N·m (9.5 kg-m, 69.0 lb-ft)
MANUAL RACK AND PINION 3B-11
D Apply grease lightly to sliding part of plunger (1) against rack.
“A”: Grease 99000-25050
D Install rack plunger (1), rack plunger spring (2) and rack damper
screw (3) and adjust rotation torque of pinion as follows.
i) After tightening rack damper screw (3) to the tightest point,
turn it back by 05 – 905 and check for rotation torque of pinion.
If it is not as specified below, adjust so that it will be within
specified torque range.
Special Tool
(A): 09944-18211
Rotation torque of pinion
0.8 – 1.3 NVm (0.08 – 0.13 kg-m, 0.6 – 0.9 lb-ft)
Also, check if rack as a whole moves smoothly.
ii) After adjustment, put rack damper screw cap (4) as deeply
as possible.
D Install new tie rod lock washer (1) as shown, and then install tie
rod (2) to steering rack (3). Align straight part “A” of washer with
flat part “B” of steering rack.
D Tighten tie rod to specified torque.
Tightening Torque
(a): 85 N·m (8.5 kg-m, 61.5 lb-ft)
Upper
D Bend lock washer to tie rod side as shown.
3B-12 MANUAL RACK AND PINION
D Before installing boot to steering rack housing (1), make sure
that rack side mount (2) is positioned as shown.
Distance “a” 1.0 – 2.0 mm (0.04 – 0.08 in.)
D Position boot (1) properly in grooves of gear case and tie rod,
and then clamp it with wire (2) and clip (3).
Wire should be new and should go around twice and be tight-
ened with its both ends twisted together. The twisted ends
should be bent in the circumferential direction. After this, check
to ensure that boot is free from twist and bent.
Apply grease to all around inner surface of hatched part.
“A”: Grease 99000-25050
D Install tie rod end lock nut and tie rod end to tie rod. Position lock
nut to marking (1) made in removal.
NOTE:
When tie rod was replaced, measure length “a” on removed
tie rod end and use it on new replacement tie rod end so as
to position lock nut properly.
INSTALLATION
For installation, reverse removal procedure, note the following
instructions.
D Tighten rack and pinion assembly mounting bolts (1) to specified
torque.
Tightening Torque
(a): 25 N·m (2.5 kg-m, 18.0 lb-ft)
< Right side > < Left side >
D Hoist engine with transmission jack (1), and then tighten engine
member rear bolts (2) to specified torque.
Tightening Torque
(a): 40 N
.
m (4.0 kg-m, 30.0 lb-ft)
MANUAL RACK AND PINION 3B-13
D Connect extension rod (1) and gear shift control shaft (2) to
transmission assembly.
Tightening Torque
(a): 6 N
.
m (0.6 kg-m, 4.5 lb-ft)
(b): 33 N
.
m (3.3 kg-m, 24.0 lb-ft)
D Install new exhaust pipe gasket and exhaust pipe (1).
Tightening Torque
(a): 55 N
.
m (5.5 kg-m, 40.0 lb-ft)
D Install tie rod ends (1) to knuckles (2). Tighten castle nuts (3) until
holes for cotter pin (4) align but within specified torque and then
bend new cotter pins (4) as shown.
Tightening Torque
(a): 43 N·m (4.3 kg-m, 31.5 lb-ft)
NOTE:
Removed cotter pin should be replaced with new one.
D Tighten tie rod end lock nuts (1) to specified torque.
Tightening Torque
(a): 45 N·m (4.5 kg-m, 32.5 lb-ft)
3B-14 MANUAL RACK AND PINION
D Be sure that steering wheel and brake discs (right and left) are
all straight ahead driving state and then insert steering lower
shaft into steering pinion shaft.
D Tighten steering lower shaft bolts to specified torque (Lower bolt
(1) first, and then upper bolt (2)).
Tightening Torque
(a): 25 N
.
m (2.5 kg-m, 18.0 lb-ft)
D Tighten wheel nuts (1) to specified torque.
Tightening Torque
(a): 85 N·m (8.5 kg-m, 61.5 lb-ft)
D After completion of installation, check wheel alignment and toe
setting referring to FRONT END ALIGNMENT in section 3A.
REQUIRED SERVICE MATERIALS
MANUAL RACK AND PINION 3B-15
MATERIAL
RECOMMENDED
SUZUKI PRODUCT
USE
Lithium Grease
(Should be applicable
for –405C~1305C)
SUZUKI SUPER GREASE E
(99000-25050)
D Sliding part of rack against steering housing (All
around rack plunger, rack bushing and rack)
D Sliding part against steering pinion
(Oil seal lip, needle bearing)
D Steering rack and pinion gear teeth
D Filled into pinion bearing plug
D Contacting parts of tie rod and rack side boots
D Rack end ball joint
09913-65210
Tie-rod end remover
09913-50121
Oil seal remover
09921-20200
Bearing remover
09944-26011
Pinion bearing plug
socket (43 mm)
09944-18211
Pinion torque checking
socket
09943-88211
Bearing installer
09925-98210
Bearing installer
09930-30104
Sliding shaft
09944-48210
Rack bush remover
3B-16 MANUAL RACK AND PINION
SPECIAL TOOL

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