STEERING GEAR AND LINKAGE ASSEMBLY

Caution

• Place copper plates, rag, or similar material in a vise. When secure the mounting bracket portion of the steering gear.

1. Assemble in the order indicated in the table.

Mounting Bushing Assembly Note

1. Apply soapy water to the rubber part of the mounting bushing.

2. Using the SSTs and a press, press the mounting bushing until the mounting bushing end comes out completely from the gear housing.

3. Reverse the gear housing, then press the mounting bushing until the mounting bushing end comes out completely from the other side. At this time, mounting bushing end and steel pipe are aligned.

Oil Seal (Gear Housing) Assembly Note

1. Install the oil seal in the rack housing using the SSTs.

2. After installation, inspect for noise by shaking the gear housing.

• If there is noise, the seal is not properly installed. Reinstall it.

Steering Rack Assembly Note

1. Take the vinyl that is included in the replace parts kit and place it over the rack threads.

2. Insert the steering rack into the gear housing.

Oil Seal and O-ring Assembly Note

1. Press the oil seal until it is flush with the edge of the rack bushing as shown.

2. Install the O-ring into the rack bushing.

Rack Bushing Assembly Note

1. After attaching the SST to the end of the steering rack, install the rack bushing to the rack housing.

Rack Stopper Assembly Note

1. Using snap ring pliers, screw the rack stopper into the rack housing until the hole on the rack stopper lines up with the oblong hole on the rack housing.

2. Insert the clip into the hole on the rack stopper.

3. Install the rack stopper by turning the rack stopper clockwise.

4. Perform a hermetic sealing inspection.

(1) Connect the SSTs to the power cylinder section of the gear housing.

(2) Apply 53.3 kPa {400 mmHg, 15.7 inHg} 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.

Oil Seal (Valve Housing) Assembly Note

1. Press the oil seal into the valve housing using the SSTs.

Upper Bearing Assembly Note

1. Press the upper bearing into the valve housing using the SSTs.

Seal Ring Assembly Note

1. Assemble the seal rings to the pinion shaft component.

2. Pull the SST over the pinion shaft component from both directions. This will correctly shape the seal ring.

3. Install the oil seal from the pinion shaft gear side.

Pinion Shaft Component Assembly Note

1. Install the pinion shaft component into the valve housing (this can be done by hand).

2. Press the oil seal into the valve housing using the SST.

Caution

• Temporarily secure the tie rod. Otherwise, the seal could be scratched when the rack moves all the way to the stroke end.

3. Insert the valve housing component into the gear housing.

4. Secure the pinion end and the lower ball bearing on the inside with the locknut.

Lower Bearing Assembly Note

1. Press the lower bearing into the gear housing using the SST.

Locknut (Housing Cover) Assembly Note

1. Temporarily attach the tie rod to the steering rack.

2. Tighten the locknut.

20-29 N·m {2.0-3.0 kgf·m, 15-21 ft·lbf}

Housing Cover Assembly Note

Caution

• Be careful not to apply too much sealant.

1. Apply sealant to the threads of the housing cover.

2. Mount the housing cover.

50-68 N·m {5.0-7.0 kgf·m, 37-50 ft·lbf}

3. Caulk one point of the housing cover and gear housing.

Adjusting Cover Assembly Note

1. Apply sealant to the threads of the adjusting cover.

2. Tighten the adjusting cover to a torque of 20-29 N·m {2.0-3.0 kgf·m, 15-21 ft·lbf} using the SSTs.

3. Loosen the adjusting cover about 25-30°.

Locknut (Adjusting Cover) Assembly Note

Caution

• Do not allow the adjusting cover to turn.

1. Tighten the locknut while securing the adjusting cover using the SSTs.

50-68 N·m {5.0-7.0 kgf·m, 37-50 ft·lbf}

2. Adjust the pinion preload as follows.

(1) Attach the SST and the pull scale to the pinion shaft.

(2) Measure the pinion rotation torque.

• If not within the specification, loosen the locknut and readjust the adjusting cover.

Standard

Center of rack ± 90°

0.8-1.3 N·m {8-14 kgf·cm, 7-12 in·lbf}

[Pull scale reading

7.9-13 N {0.8-1.4 kgf, 1.8-3.0 lbf}]

Tie Rod Assembly Note

1. Secure the teeth section of the rack in the vise.

2. Tighten the tie rod using the SST.

79-98 N·m {8.0-10.0 kgf·m, 58-72 ft·lbf}

3. Caulk the washer.

Boot Assembly Note

1. Install the boot band onto the large end of the boot as shown.

2. Verify that the boot is not twisted and dented while moving the rack fully right and left.

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.

Tie-rod End Assembly Note

1. Assemble the tie-rod end so that the marks made before disassembly are aligned.