Assembly

STEERING GEAR AND LINKAGE ASSEMBLY





1. Assemble in the order indicated in the table.

Tie-rod End Boot Assembly Note
1. Wipe the grease off the ball joint.
2. Put a small amount of lithium-based grease into a new dust boot.





3. Install the dust boot onto the tie-rod end using the SST and a press.
4. Wipe away any excessive grease.

Mounting Rubber Assembly Note
1. Apply soapy water to the rubber part of the mounting rubber.





2. Press the mounting rubber until the mounting rubber end comes out completely from the gear housing using the SSTs and a press.

Note:
^ Mounting rubber end and steel plate shall be aligned.





3. Reverse the gear housing, then press the mounting rubber until the mounting rubber end comes completely out the other side.

Oil Seal Assembly Note 1
1. Install a new O-ring and new seal ring to the rack piston.
2. After installing the seal ring, seat it properly at the piston circumference.





3. Install a new oil seal to the SST (49 B032 319) using the SST (49 B032 318).
4. Remove the SST (49 B032 318).





5. Using the SST, place the oil seal at the edge of the steering rack's piston and remove the SST.
6. Install a new inner guide to the steering rack.

Caution:
^ When pressing in, do not apply a load pressure of more than 39.2 MPa 1400 kgf/ cm2, 5,690 psi). Doing so will damage the oil seal and inner guide.





7. After installing the steering rack to the gear housing, press the oil seal and inner guide using the SST until the force required suddenly increases.

Holder Assembly Note
1. Apply grease to the U-gasket and O-ring.
2. Assemble the U-gasket and O-ring into the holder.





3. Assemble the SST to the steering rack.





4. Assemble the holder using the SST.





5. Stake the holder to the cylinder using a punch.

Oil Seal Assembly Note 2
1. Apply grease to a new oil seal.





2. Press in the new oil seal using the SSTs.

Upper Bearing Assembly Note
1. Apply grease to a new upper bearing.





2. Press in the new oil seal using the SSTs.

Seal Ring Assembly Note





1. Install a new seal ring to the valve part of the pinion shaft using the SST.
2. After installing it, seat it properly using the SST.
3. Install the snap ring.

Adjusting Cover Assembly Note
1. Set the rack to the center position.





2. Tighten the adjusting cover to 20 Nm (2.0 kgf-m, 14 ft. lbs.) 3 times, then return it 42° using the SST.
3. Apply sealant to the threads of the locknut.
4. Attach the locknut.





5. Measure the pinion torque using the SST and a pull scale.
^ If not as specified, repeat Step 2 through 5.

Standard
Center of rack ±90° 0.8 - 1.1 Nm (8 - 11 kgf-cm, 7 - 9 inch lbs.) [Pull scale reading 8 - 11 N (0.8 - 1.1 kgf, 1.7 - 2.4 lbs.)]





6. Install the locknut using the SST.
Tightening torque 40 - 49 Nm (4.0 - 5.0 kgf-m, 29 - 36 ft. lbs.)

Hermetic Sealing Inspection





1. Connect the SSTs to the power cylinder section of the gear housing.
2. Apply 53.3 kPa (400 mm Hg, 15.7 in Hg) vacuum with a vacuum pump and verify that it is held for at least 30 seconds.
^ If the vacuum is not held, replace the oil seal.