Disassembly and Reassembly

Disassembly

1. Remove the dust packing & cap (A) from the pinion housing.




2. Loosen the lock nut and then remove the tie rod end (B) and lock nut (A) from the tie rod.




3. Remove the bellows clip (A) and band (B) and then pull the bellows (C) away from the end of the tie rod.




4. Remove the tie rod (B) from the rack bar (A) by unscrewing the tie rod inner ball joint.




5. Remove the plug (A) from the pinion housing.




6. Remove the oil seal (B) from the plug (A).




7. Remove the yoke plug (A) and spring (B) and then pull out the support yoke (C).




8. Remove the O-rings (B) from the support yoke assembly (A).




9. Pull the pinion assembly (A) out of the pinion housing.




10. Pull the rack bar (A) out of the rack housing.






Reassembly

1. Apply the grease to rack gear teeth and then insert the rack bar (A) into the rack hosing.




2. Insert the pinion assembly (A) into the pinion housing.




3. Tap the top of the pinion assembly with a plastic hammer to seat the pinion assembly thoroughly.




4. Assemble new O-rings (B) to support yoke (A).




5. Insert the support yoke assembly (C) into the housing.
6. Apply the sealant to the thread of the yoke plug and then assemble the yoke plug (A) and the yoke spring (B) together.




7. Apply the grease to the edge of the new oil seal (B) and then assemble it to the pinion plug (A).




8. Apply the sealant to the thread of the plug and then assemble the pinion plug (A) to the housing.

Tightening torque :
60 - 80N.m (6.0 - 8.0kgf.m, 43 - 58lb-ft)





9. Apply loctite (Three bond-1374) to the thread of the tie rod inner ball joint and then assemble the tie rod (A) to the rack bar (B).

Tightening torque :
110 - 130N.m (11.0 - 13.0kgf.m, 65 - 94lb-ft)





10. Assemble new bellows band (A) to the bellows.




11. Apply the grease (Kyoto Yushi-One Luber2128 to the portion (D) of the tie-rod.
12. Apply the sealant (Three bond-1141E) to the bellows mating surface of the rack housing.
13. Assemble the bellows (C) to rack housing and then tighten the bellows clip (A) and band (B).




14. Assemble the lock nut (A) and tie rod end (B) to tie rod.