Assembly

1. Apply Dexron II or Diamond ATF SP automatic transaxle fluid to entire surface of rack oil seal.
2. Install back-up washer and oil seal to rear of gear housing.
3. Apply multi-purpose grease SAE J310 NLGI No. 2, or equivalent, to entire surface of needle bearing.
4. Set scribed side of needle bearing in tool No. 09432-21600, or equivalent, and install it into gear housing.
5. Apply multi-purpose grease SAE J310 NLGI No. 2, or equivalent, to new ball bearing and install using tool No. 09222-21100, or equivalent.
6. Apply Dexron II or Diamond ATF SP automatic transaxle fluid to entire surface of rack bushing oil seal.
7. Install oil seal in rack bushing.
8. Apply multi-purpose grease SAE J310 NLGI No. 2, or equivalent, to entire surface of O-ring and install it in rack bushing and teeth. Do not plug vent hole in rack with grease.
9. Insert rack into gear housing.
10. Install rack bushing and rack stopper.
11. Push in rack stopper until circlip groove of rack stopper is aligned with notched hole of rack housing. Install circlip while turning rack stopper. Circlip end should not be visible through notched hole of rack housing.
12. using bearing and seal tool No. 09432-21600, or equivalent, install oil seal and ball bearing in valve body.
13. Apply Dexron II or Diamond ATF SP fluid and multi-purpose grease SAE J310 NLGI No. 2, or equivalent, to pinion valve assembly and install in gear housing assembly.
14. Apply Dexron II or Diamond ATF SP fluid and then use tool No. 09434-14200, or equivalent, to install seal in valve body housing.
15. Install valve body assembly with seal ring to gearbox.
16. Install new tab washer and tie rod and stake tab washer end at two points over tie rod. Align new tab washer pawls with rack grooves.
17. With pinion turned fully clockwise, tighten new self-locking nut.
18. Apply semi-drying sealant to threaded section of end plug and tighten to specifications.
19. Stake end plug at two points on its circumference with a punch.
20. Install bushing, rack support, rack support spring and rack support cover. Apply semi-drying sealant to threaded section of rack support cover before installation.
21. With rack placed in center position, attach rack support cover to gear housing. Tighten rack support cover to specifications using tool No. 09565-21100, or equivalent. Loosen rack support cover approximately 10° and tighten rack support cover locking nut to specifications.
22. Tighten feed tube to specifications.
23. Apply multi-purpose grease SAE J310 NLGI No. 2, or equivalent, to bellows mounting position (fitting groove) of tie rod.
24. Install attaching new band to bellows.
25. Install bellows in position, taking care not to twist it.
26. Fill dust cover inner side and upper lip with multi-purpose grease SAE J310 NLGI No. 2, or equivalent, and place dust cover in position with clip ring attached in groove of tie rod end.
27. Install tie rods so that length of left and right tie rods are equal. Standard tie rod length is 6.86-6.94 inches.
28. Confirm total pinion preload.