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Reassembly (Amigo, Passport/Rodeo, Trooper & VehiCROSS)

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2000 Isuzu VehiCROSS, 2000 Isuzu Trooper, 2000 Isuzu Rodeo, 2000 Isuzu Hombre, and 2000 Isuzu Amigo. However, it is still accessible from the selected car via links, so may be relevant.
  1. If sector shaft bearing was removed, install NEW bearing flush with the recessed face of housing and with name of bearing facing out toward top cover.
  2. Install sector shaft seal ring and dust seal ring in housing. Apply a thin coat of grease to lip of seals and "O" rings. Install valve housing "O" ring, piston "O" ring and piston seal ring. DO NOT allow "O" rings to twist.
  3. Install seal ring to rack piston by expanding it to fit over "O" ring. See Fig 1. Apply a thin coat of grease to entire circumference of seal ring.
    Fig 1: Installing Rack Piston Seals (Amigo, Passport/Rodeo, Trooper & VehiCROSS)
    G96J20254Courtesy of ISUZU MOTOR CO.
  4. Insert ball screw and housing assembly into gear assembly, while keeping ball screw and housing assembly horizontal. Install valve housing bolts and tighten to specification. See TORQUE SPECIFICATIONS . Install NEW stub shaft oil seal into valve housing.
  5. Using Seal Driver (J-26508), install back-up ring, retaining ring and dust cover in reverse order of disassembly. Back-up ring and retaining ring should be installed so ring faces with rounded outer circumferences turn toward oil seal.
  6. Install hose fitting to valve housing with a NEW "O" ring. Tape sector shaft spline to protect bushing and seal rings. Install sector shaft while aligning sector teeth and rack teeth in straight-ahead position. See Figure.
  7. Thread adjusting screw into top cover. Turn adjusting screw counterclockwise until top cover contacts housing. Align cover to housing and continue turning screw 2 more turns. Install top cover bolts.
  8. Check if sector and rack are installed properly by turning stub shaft lock-to-lock. Sector and rack are installed properly if stub shaft turns more than 4 turns.
  9. Adjust backlash between rack piston worm gear and sector shaft teeth by placing sector shaft in middle of its travel (straight-ahead wheel position). Install INCH-lb. torque wrench and socket to stub shaft. Check starting torque.
  10. If starting torque is not 3.5-5.3 INCH lbs. (.4-.6 N.m), adjust starting torque with adjusting screw. To decrease backlash, turn clockwise. Install NEW lock nut.
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