Assembly
STEERING GEAR AND LINKAGE ASSEMBLY
1. Assemble in the order indicated in the table.
BACKUP WASHER ASSEMBLY NOTE
1. Apply Automatic Transmission Fluid (ATF) to the new oil seal.
2. Install the backup washer and oil seal using the Special Service Tools (SSTs).
3. After installing, shake the gear housing and verify that the backup washer does not rattle.
^ If it rattles, remove the oil seal and backup washer, and install them.
STEERING RACK ASSEMBLY NOTE
1. Apply Automatic Transmission Fluid (ATF) to a new O-ring and seal ring.
2. Install the O-ring and seal ring in the piston groove.
3. Apply grease to the friction surface and teeth of the rack.
4. Slide the vinyl sleeve (supplied in the seal kit) over the rack, and slide the rack in from the tube side.
5. Remove the vinyl sleeve.
OIL SEAL AND O-RING ASSEMBLY NOTE
1. Apply Automatic Transmission Fluid (ATF) to a new 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.
3. Apply ATF to the new O-ring.
4. Install the O-ring onto the groove of the rack bushing.
RACK BUSHING ASSEMBLY NOTE
1. Apply Automatic Transmission Fluid (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 ASSEMBLY NOTE
1. Using snap-ring pliers, screw the rack stop into the rack housing until the hole on the rack stop lines up with the oblong on the rack housing.
CLIP ASSEMBLY NOTE
1. Insert the clip into the hole on the rack stop.
2. Install the rack by turning the rack stop clockwise.
3. Perform the hermetic inspection.
1. Connect the SSTs (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 pressure is maintained for at least 30 seconds.
^ If the vacuum is not held, replace the oil seal.
SEAL RING ASSEMBLY NOTE
1. Apply Automatic Transmission Fluid (ATF) to new seal rings.
2. Install the seal rings onto the pinion shaft component.
3. Pass the pinion shaft component back and forth through the SST until the seal rings are set.
4. Install the oil seal on the gear side of the pinion shaft.
OIL SEAL ASSEMBLY NOTE
1. Apply grease to the lip of a new oil seal.
2. Press the oil seal into the valve housing using the SSTs.
3. Press the upper bearing in the valve housing using the SSTs.
BALL BEARING ASSEMBLY NOTE
1. Press the ball bearing into the pinion shaft using the SSTs.
ADJUSTING COVER ASSEMBLY NOTE
1. Apply sealant to the threads of the adjusting cover.
2. Tighten the adjusting cover to 20 - 29 Nm (2.0 - 3.0 kgf-m, 16 - 21 ft. lbs.) using the SSTs, and return it 25° -30°.
3. While keeping the adjusting cover from turning, tighten the locknut using the SST.
Tightening torque
50 - 68 Nm (5.0 - 7.0 kgf-m, 37 - 50 ft. lbs.)
4. Measure 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°.)
^ If not within the specification, adjust the adjusting cover.
Pinion preload
0.5 1.3 Nm (5 - 14 kgf-cm, 5 - 12 inch lbs.) max.
Pull scale reading
5 - 13 N (0.5 - 1.4 kgf, 1.2 - 3.0 lbs.)
TIE ROD ASSEMBLY NOTE
1. Install the tie rod using the SST.
Tightening torque
79 - 98 Nm (8.0 - 10.0 kgf-m, 58 - 72 ft. lbs.)
2. Bend the new washer at the two points using a punch.
BOOT ASSEMBLY NOTE
1. Apply grease to the inner surface of the small end of the boot.
2. Install the boot and the new boot clamp as shown in the figure.
3. Install the new small boot clamp.
4. Verify that the boot is not twisted and dented while moving the rack fully forward and back.
TIERED END BOOT ASSEMBLY NOTE
1. Wipe the grease on the ball joint.
2. Put a small amount of lithium-based grease into the new boot and set it onto the tie-rod end.
3. Install the boot onto the tie-rod end using the SST and a press.
4. Wipe away any excessive grease.
TIE-ROD END ASSEMBLY NOTE
1. Assemble the tie-rod end so that the marks made before disassembly are aligned.