Front

1. Install new O-ring on rack with its narrow edge facing out.
2. Coat pinion seal ring guide with power steering fluid, then slide onto rack, big end first.
3. Position new piston seal ring on piston seal ring guide tool No. 07LAG-SM40100, or equivalent, slide seal ring onto big end of tool, then pull it off into piston groove on top of O-ring.
4. Coat piston seal ring and piston seal ring sizing tool No. 07LAG-SM40200, or equivalent, with power steering fluid.
5. Carefully slide tool onto rack and over piston ring, then rotate tool as you move it up and down to seat piston ring.
6. Coat new O-rings with grease, then install onto cylinder cap.
7. Slide cylinder cap onto seal retainer.
8. Install snap ring and O-ring on seal retainer.
9. Grease sliding surface of steering rack bushing B, then install bushing on steering rack with groove of bushing facing steering rack piston.
10. Grease sliding surfaces of new cylinder end seal and cylinder end slider tool No. 07LAG-SM40300, or equivalent, then place seal on tool with its grooved side facing opposite slider.
11. Install tool and cylinder end seal on rack. Ensure rack teeth do not face slot in tool.
12. Separate cylinder end seal from tool, then remove tool from rack.
13. Fit seal retainer on steering rack.
14. Push rack bushing B toward seal retainer until cylinder end seal is seated in retainer. Fit seal stopper ring in groove of seal retainer securely, then grease rack.
15. Install retainer washer on gear housing.
16. Place gear housing on bench and insert seal retainer and steering rack into gear housing.
17. Coat inside surface of cylinder with power steering fluid.
18. Slide cylinder over rack and into gear housing, then press into housing until it seats.
19. Install cylinder spring over rack, then coat bushing A with power steering fluid and install it onto spring.
20. Wrap end of steering rack with vinyl tape, then coat tape with grease.
21. Coat inside surface of cylinder with power steering fluid, then install cylinder end seal with its grooved side facing out.
22. Install O-ring and back-up ring on gear housing.
23. Carefully position cylinder on gear housing and loosely install four bolts. Be careful no to damage end seal of cylinder housing.
24. Remove vinyl tape from steering rack.
25. Ensure mating surfaces of gear housing and cylinder housing are aligned by pushing together. While holding together, tighten four attaching bolts to specifications.
26. Insert steering rack into cylinder housing, being careful not to damage steering rack sliding surface.
27. Install steering pinion into pinion holder, then the circlip securely into pinion holder groove with its tapered side facing outward.
28. Grease sealing lip of steering pinion seal, then install it onto gear housing.
29. Wrap spline area of steering pinion with vinyl tape and grease surface of tape.
30. Grease new O-ring and install it into gear housing.
31. Slide gear housing cap over steering pinion, being careful not to damage sealing lip or dislodge pinion seal spring.
32. Tighten gear housing cap attaching bolts to specifications.
33. Remove vinyl tape from steering pinion, then install new lock washer in groove of steering rack.
34. Holding steering rack with a wrench, tighten rack end to specifications.
35. After tightening rack end, stake lock washer in four places.
36. Apply steering grease to circumference of rack end housing.
37. Coat rack end groove and inside of boot with silicone grease.
38. Install boots on rack end with tube clamps.
39. Install tie rod ends, then tighten tie rod end locknut to specifications.
40. Grease new O-ring and install it in groove of rack guide screw.
41. Coat rack guide sliding surface with grease, then install rack guide, spring and rack guide screw onto gear housing.
42. Adjust rack guide at center of rack stroke as necessary.
43. On models with 2-wheel steering, proceed as follows:
a. Tighten rack guide screw until it compresses spring and seats against rack guide, then loosen it.
b. Torque rack guide screw to 34 inch lbs. and back it off approximately 20 degrees, then install locknut on rack guide screw.
c. Using suitable tool to hold the rack guide screw, tighten locknut.
44. On models with 4-wheel steering, proceed as follows:
a. Install locknut on sub-steering angle sensor.
b. Grease new O-ring and install it in groove of sub-steering angle sensor.
c. Install rack guide screw, then coat rack guide sliding surface with grease.
d. Install rack guide, spring, O-ring and front sub-steering angle sensor on gear housing. Adjust rack guide at center of rack stroke as necessary.
e. Tighten rack guide screw until it compresses the spring and seats against rack guide, then loosen it.
f. Tighten rack guide screw to specifications, then back it off approximately 20 degrees and install locknut on rack guide.
g.While holding guide screw, tighten locknut to specifications.
45. Coat O-rings with grease and install together with orifices.
46. Coat O-ring and pinion holder pin with grease, then install into valve body unit.
47. Install valve body unit onto gear housing, tighten attaching bolts to specifications. When installing valve body unit, be careful not to hit pinion holder pin and ensure O-rings are in place and not pinched.
48. When installing boot band, ensure rack is in its straight ahead position.

Fig. 19 Steering Gear Boot Band Installation:

49. Install boot band so locking tabs of band are in range, Fig. 19.
50. Install new boot bands on boot and bend both sets of locking tabs.
51. Lightly tap on doubled-over portions to reduce their height.
52. Install band cushion and air hose band, then position band, Fig. 19, and tighten it.
53. Install air hose, then slide rack right and left to ensure boots are not deformed or twisted.