2WD
ASSEMBLYNote: With the oil seal, inner guide, steering rack and outer box installed to the gear box, check to confirm the air-tightness of the cylinder part of the gear box.
Steering Rack
1. Install a new oil seal and new seal ring to the rack's piston.
2. After installing the seal ring, seat it properly at the piston circumference.
3. Install the oil seal and inner guide to the SST.
4. Using the place the oil seal and inner, guide at the edge of the steering rack's pinion.
5. After mounting the steering rack to the gear box, use a press to install the oil seal and inner guide to the correct position.
Caution:
- When pressing in, do not apply a load pressure of more than 29,430 kPa (300 kg/cm2, 4,266 psi), because to do so will damage the oil seal and inner guide.
- Apply grease to the seal ring, oil seal and inner guide.
Outer Box Assembly
1. After installing the SST to the rack, install the outer box, and use the SST to tighten.
Oil Seal
1. Use the SST to install a new oil seal to the gear housing.
Note: Apply grease to the oil seal.
Seal Ring
1. Use the SST to install a new seal ring to the valve part of the pinion shaft.
2. After installing it, use the SST to seat it properly.
3. Use the SST to install the pinion shaft assembly to the gear housing.
Plug
1. Use the SST to press in a new oil seal.
2. Press in by placing the flat plate against the bearing.
Caution: Apply grease to the oil seal and bearing.
3. Use the SST to tighten the plug to the gear housing.
Adjusting Cover
1. Apply sealant to the adjusting cover and temporarily tighten it to a torque of 11 Nm (110 cm-kg, 95 in-lb).
2. Move the rack back and forth approx. 3 times and loosen the adjusting cover.
3. Retighten the adjusting cover 10 the specified torque and then loosen it 0-40 degrees.
Tightening torque:
4.4-5.4 Nm (45-55 cm-kg, 39-48 in-lb)
4. Tighten the locknut with the SST.
5. Measure the pinion starting torque with the SST and a pull scale.
Starting torque:
At +/- 90 degrees from the straight-ahead position
1.0-1.3 Nm (10-14 cm-kg, 8.7-12 in-lb)
(Pull scale reading: 1.0-1.4 kg [2.2-3.1 lb])
At other position:
1.6 Nm (17 cm-kg, 14.7 in-lb) max. (Pull scale reading: 1.7 kg [3.7 lb] max.)
6. If not as specified, repeat steps 3 to 5.
Tie-rod
Note: Install the tie-rod (with air bled out) at the rack housing side.
Cylinder Air-Tightness Check
1. Install the SST to the cylinder part of the gear housing.
2. Using a vacuum pump, apply a vacuum of 400 mmHg and check to be sure that the vacuum is maintained for 30 seconds.
3. If there is any leakage, replace the oil seal.