Installation
INSTALLATIONBackup Washer and Oil Seal
1. Apply ATF to the oil seal.
2. Install the backup washer and oil seal with the SST.
3. After installing, shake the gear housing and verify that the backup washer does not rattle.
4. If it rattles, remove the oil seal and backup washer and reinstall them.
Rack
1. Apply grease to the friction surface and teeth of the rack.
2. Slide the vinyl sleeve supplied in the seal kit over the rack and slide the rack in from the tube side.
3. Remove the vinyl sleeve.
Oil Seal and 0-ring
1. Apply ATF to the oil seal.
2. Set a plate on the oil seal and press it into the rack bushing until the plate contacts the edge of the rack bushing.
Rack Bushing
1. Apply ATF to the friction surface of the rack bushing.
2. Slide the SST over the end of the rack and install the rack bushing.
Rack Stop
1. Press the rack stop in the rack housing with snap-ring pliers until the holes of the rack housing and the rack bushing are aligned.
2. Insert the clip through the holes and turn the rack stop to install it.
3. After installing, inspect for airtightness as follows.
(1) Connect the SST (adapters) to the cylinder housing.
(2) Connect the vacuum pump to the SST (hose) and apply 400 mm Hg (15.7 in Hg) vacuum.
(3) Verify that vacuum is held for at least 30 seconds. If not, replace the oil seal.
Needle Bearing
1. Press in the needle bearing with the SST.
Seal Ring and 0-ring (ECPS)
1. Apply ATF to the seal rings.
2. Install the seal rings and 0-rings (ECPS) onto the pinion shaft assembly.
3. Pass the pinion shaft assembly back and forth through the SST to form the seal rings.
Oil Seal and Upper Bearing
1. Apply grease to the oil seal lip.
2. Press the oil seal into the valve housing with the SST.
3. Press the upper bearing in the valve housing with the SST.
After Installation:
(1) Check for fluid leakage.
(2) Bleed air from the system.
(3) Check the steering angle and toe-in and adjust if necessary.
Lower Bearing
1. Apply grease to the teeth of the rack.
2. Insert the pinion shaft assembly into the gear housing.
3. Apply grease to the lower bearing and install it onto the pinion shaft.
4. Install the housing cover and tighten it until the tightening force suddenly increases.
Note: The lower bearing is seated by tightening the housing cover.
5. Remove the housing cover.
Valve Housing Assembly
1. Apply ATF to the outside edge of the oil seal and apply grease to the oil seal lip.
2. Press the oil seal into the valve housing with the SST.
3. Install the valve housing.
Adjusting Cover
1. Apply sealant to the threads of the adjusting cover.
2. Tighten the adjusting cover to 20-29 N.m (2.0-3.0 m-kg, 14-22 ft-lb) with the SST and return it 25-30 deg.
Note: Turning angle is determined with the SST.
3. Tighten the locknut with the SST.
Tightening torque:
49-69 N.m (5.0-7.0 m-kg, 36-51-ft lb)
Caution: Do not allow the adjusting cover to turn.
4. Inspect the pinion preload as follows.
(1) Attach the SST and a pull scale to the pinion shaft.
(2) Measure the pinion preload. (Center of rack +/- 90 deg.)
Pinion preload: 1.5 N.m (15 cm-kg, 13 in-lb) max.
Pull scale reading: 1.5 kg (3.3 lb) max.
(3) If not within specification, repeat Steps 2 and 3.
Tie-Rod
1. Install the tie-rod with the SST.
Tightening torque:
78-98 N.m (8.0-10.0 m-kg, 58-72 ft-lb)
2. Stake the washer with a punch.
Boot Clamp (outer)
1. Install the boot clamp as shown in the figure.