1. Using a press, install the bushing to gearbox installation portion.

2. Insert the ST to rack.

3. Install the seal ring and O-ring to piston portion of rack.

4. Using the ST, form the seal ring properly.

5. Using the ST A and ST B, attach the oil seal to ST C.

NOTE:

6. Insert the ST C with oil seal assembled from the gear side of rack. Remove the oil seal from ST C near piston, and then remove the ST C from rack.

7. Install the back-up washer from the gear side of rack.

8. Check the threaded end of holder and gearbox cylinder end for burrs, damage, etc. Correct if faulty.

9. 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.

10. Temporarily tighten the holder to gearbox cylinder.

11. Put a mark at the specified position measured from the end surface of ST, as shown in the figure.

^*1: For models, refer to the “ID” section.

12. Set the ST to the end of rack.

13. Using a press, press-fit until the mark on the ST is aligned with the end surface of the holder.

14. Remove the ST and holder.

15. Insert the outer side oil seal into the rack using the same procedure as steps 5) and 6).

16. Put the ST and pipe through the rack, and press-fit the outer side oil seal using a press.

17. Secure the gearbox in a vise using ST.

18. Tighten the holder.

19. Using the ST, crimp so that the diameter of punch hole is 2 — 2.5 mm (0.08 — 0.10 in) and is aligned to the position of 2 mm (0.08 in) from gearbox cylinder end surface.

20. Put a vinyl tape around the spline portion and apply genuine grease to the dust cover and install to valve assembly.

CAUTION:

21. Apply the genuine grease to the pinion gear and bearing of valve assembly.

22. Install new O-ring to valve assembly. Insert the valve assembly into place while facing the rack teeth toward pinion.

23. Tighten the bolts alternately to secure the valve assembly.

CAUTION:

24. 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.

CAUTION:

25. Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.

26. 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.

27. Tighten the adjusting screw to the specified torque, then loosen it.

28. Tighten the adjusting screw to the specified torque, then loosen it within 20°.

29. Remove the tie-rod.

30. Adjust the turning resistance of gearbox so that it is within specification using adjusting screw.

31. Attach the lock nut into adjusting screw, and while holding the adjusting screw with wrench, tighten the lock nut using ST.

NOTE:

32. Extend the rack approx. 40 mm (1.57 in) from steering body.

33. Install the tie-rod and new lock washer into rack.

34. Bend the lock washer and crimp it.

CAUTION:

35. Apply a coat of grease to the tie-rod groove, and then install the boot to the housing.

CAUTION:

NOTE:

36. Install a new boot band. Using band clamp pliers, crimp it so that the clearance of crimping portion becomes 2 mm (0.079 in) or less.

37. Fix the boot end with small clip.

38. After installing, check that the boot end is installed to the groove of the tie-rod.

39. 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.

40. 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.

41. Remove the gearbox from ST.

42. Install the four pipes on gearbox.

1. Clean all parts and tools before reassembling.

2. Apply a coat of specified power steering fluid to the inner wall of valve housing.

3. Apply grease to the oil seal.

4. Verify the direction of oil seal.

5. Position the oil seal and bearing to housing. Using the ST and a press, install the oil seal and bearing to the valve housing.

6. Apply vinyl tape to the groove of pinion.

7. Install the wave washer and oil seal to pinion, and then remove the vinyl tape.

8. Attach the ST to pinion, and install the seal ring and O-ring.

9. Remove the ST GUIDE, and form the seal ring properly using ST FORMER.

10. Put vinyl tape around pinion shaft spline to protect oil seal from damage.

11. Install the valve to pinion, and install the snap ring.

12. Attach the pinion & valve assembly into the valve housing.

13. Using a press, push the outer race of bearing and press-fit the pinion & valve assembly into housing.

14. Apply the specified grease to dust cover.

15. Install the dust cover on valve assembly.

CAUTION:

16. Apply the genuine grease to the pinion gear and bearing of valve assembly.

17. Install new O-ring to valve assembly.

18. Insert the valve assembly into place while facing the rack teeth toward pinion.

19. Tighten the bolts alternately to secure the valve assembly.

CAUTION:

20. Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.

21. 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.

22. Tighten the adjusting screw to the specified torque, then loosen it.

23. Tighten the adjusting screw to the specified torque, then loosen it within 20°.

24. Adjust the turning resistance of gearbox so that it is within specification using adjusting screw.

25. Attach the lock nut into adjusting screw, and while holding the adjusting screw with wrench, tighten the lock nut using ST.

NOTE:

26. Remove the gearbox from ST.

27. Install the four pipes on gearbox.