1. Apply a coat of grease to the inside and outside of the new oil seal.
Steering grease:
VALIANT GREASE M2 (Part No. 003608001)
2. Verify the direction of the oil seal and installation position. Using the ST and a press, press-fit the oil seal into the gearbox.
| ST 34199AE130 | GEARBOX OIL SEAL INSTALLER |
|
(1) |
Oil seal |
3. Attach the steering body to ST as shown in the figure. Apply a coat of grease to needle bearing.
| ST1 926200000 | STAND |
| ST2 34199AG000 | BOSS D |
CAUTION:
Make sure the needle bearing is free from defects. If it is faulty, replace the steering body with a new part.
|
(1) |
Clamp |
4. Using the ST B and ST C, attach the oil seal to ST A.
| ST 34199FE040 | INSTALLER A, B, C |
NOTE:
Face the oil seal in the direction as shown in the figure.
|
(A) |
Oil seal |
5. Insert the ST A with oil seal assembled from the gear side of rack. Remove the oil seal from ST A near piston, and then remove the ST A from rack.
|
(A) |
Oil seal |
|
(B) |
Rack |
|
(C) |
Piston |
6. Install the back-up washer from the gear side of rack.
|
(1) |
Oil seal |
|
(2) |
Back-up washer |
|
(3) |
Rack |
7. Apply a coat of grease to the grooves in rack, sliding surface of sleeve and sealing surface of piston. Then insert the rack into steering body from cylinder side.
8. Temporarily tighten the holder to gearbox cylinder.
9. Put a mark at the position of 10 mm (0.39 in) from the end surface of the ST as shown in the figure.
| ST 34199FE000 | INSTALLER & REMOVER |
|
(1) |
10 mm (0.39 in) |
|
(2) |
Put a mark. |
10. Attach the ST to the rack end surface.
| ST 34199FE000 | INSTALLER & REMOVER |
11. Using a press, press-fit until the mark on the ST is aligned to the end surface of the holder.
|
(1) |
Marked position |
|
(2) |
Holder |
12. Remove the ST and the holder.
13. Insert the outer side oil seal to the rack in the same procedure as in step 4) and 5).
| ST 34199FE040 | INSTALLER A, B, C |
14. Make the ST2 pass through the rack, and then press in the rack and ST2 using a press.
Press in the outer side oil seal until the ST1 and ST2 comes into contact with each other and the rack end surface is aligned to the end surface of the ST2.
| ST1 34199FE050 | GUIDE |
| ST2 34199FE060 | INSTALLER |
|
(1) |
Outer side oil seal |
|
(2) |
Rack piston |
|
(3) |
Inner side oil seal |
15. Install a new holder to the cylinder side of steering body.
Tightening torque:
90 N·m (9.1 kgf-m, 65.7 ft-lb)
16. Using the ST, crimp the steering body at one point less than 3 mm (0.12 in) from holder.
CAUTION:
Be careful not to deform the holder.
| ST 34099FA060 | PUNCH HOLDER |
|
(A) |
Holder |
|
(B) |
3 mm (0.12 in) |
17. Roll a vinyl tape on the serration portion of valve assembly, and then apply grease on the tape surface.
|
(1) |
Vinyl tape |
18. Apply a coat of grease on the gear teeth of the valve assembly, and then attach the valve assembly taking care not to scratch oil seal and seal ring.
|
(1) |
Seal ring |
|
(2) |
Oil seal |
19. Apply grease on the oil seal circumference, and then press it into the plug using ST and a press. Replace the O-rings of plug circumference with new O-rings.
| ST 34199AE110 | OIL SEAL PLUG INSTALLER |
CAUTION:
Install the oil seal paying attention to correct direction.
|
(1) |
Plug |
|
(2) |
O-ring |
|
(3) |
Oil seal |
20. Attach the plug using ST.
| ST 34199AE090 | PLUG WRENCH |
Tightening torque:
64 N·m (6.5 kgf-m, 47.0 ft-lb)
|
(1) |
Plug |
21. Install the dust cover, and remove the vinyl tape.
|
(1) |
Dust cover |
22. Temporarily tighten the tie-rod to the rack end, and then operate the rack from lock to lock for two or three times to make it fit in. Remove any grease blocking the air vent hole.
CAUTION:
If operating the rack from lock to lock without installing tie-rods, it may damage the oil seal. Always install the tie-rods LH and RH.
23. Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.
Liquid gasket:
THREE BOND 1141 (Part No. 004403006)
|
(1) |
Apply liquid gasket to at least 1/3 of entire perimeter. |
24. Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert the sleeve into steering body.
Charge the adjusting screw with grease, and then insert the spring into adjusting screw. Then install on the steering body.
|
(1) |
Sleeve |
|
(2) |
Spring |
|
(3) |
Adjusting screw |
25. Tighten the adjusting screw to the specified torque, then loosen it.
Tightening torque:
9.8 N·m (1.0 kgf-m, 7.2 ft-lb)
26. Tighten the adjusting screw to the specified torque, then loosen it.
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
27. Tighten the adjusting screw to the specified torque, then loosen it approx. 30°.
Tightening torque:
4.9 N·m (0.50 kgf-m, 3.6 ft-lb)
28. Remove the tie-rod.
29. Check that the play, or looseness, is within the standard value. 
30. Install the lock nut. While holding the adjusting screw with wrench, tighten the lock nut using ST.
| ST 926230000 | SPANNER |
Tightening torque (lock nut):
39 N·m (4.0 kgf-m, 28.9 ft-lb)
NOTE:
Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
31. Install the tie-rod into rack.
Tightening torque:
90 N·m (9.1 kgf-m, 65.7 ft-lb)
NOTE:
Check the mating face of rack and tie-rod for foreign matter such as dust etc.
32. Apply a coat of grease to the tie-rod groove, and then install the boot to the housing.
NOTE:
Make sure that the boot is installed without unusual inflation or deflation.
33. Crimp the boot so that the clearance of the boot band crimp portion becomes 2 mm (0.08 in) or less.
NOTE:
Use a new boot band.
|
(A) |
Boot band |
|
(B) |
2 mm (0.08 in) or less |
34. Fix the boot end with small clip.
|
(1) |
Clip |
35. After installing, check that the boot end is installed to the groove of the tie-rod.
36. If the tie-rod end has been removed, screw in lock nut and tie-rod end to the screwed portion of tie-rod, and tighten the lock nut temporarily in a position as shown in the figure.
Installed tie-rod length L:
31 mm (1.22 in)
37. Inspect the gearbox as follows:
“A” Holding the tie-rod end, repeat lock to lock several times as quickly as possible.
“B” Holding the tie-rod end, turn it slowly at a radius several times as large as possible.
Finally, make sure that the boot is installed in the specified position without inflating.
38. Remove the gearbox from ST.
| ST1 926200000 | STAND |
| ST2 34199AG000 | BOSS D |
39. Install the pipes A and B to the steering body and control valve housing.
Tightening torque:
T1: 20 N·m (2.0 kgf-m, 14.5 ft-lb)
T2: 24 N·m (2.4 kgf-m, 17.4 ft-lb)
|
(1) |
Pipe A |
|
(2) |
Pipe B |