Reassembly

REASSEMBLY

1. Apply the specified fluid to the entire surface of the rack oil seal.

Recommended fluid : PSF-III


2. Install the backup washer and oil seal(A) to the specified position in the rack housing.




3. Apply the specified fluid to the entire surface of the rack bushing oil seal.

Recommended fluid : PSF-III


4. Install the oil seal(A) in the rack bushing(B).




5. Apply the specified fluid to the entire surface of the O-ring and install it in the rack bushing.
6. Apply the specified grease to the rack teeth.

Recommended grease
Multipurpose grease SAE J310a NLGI No.2


NOTE:
Do not plug the vent hole(A) in the rack with grease.




7. Insert the rack(A) into the rack housing(B) and install the rack bushing(C) and rack stopper(D).




8. Push in the rack stopper until the clip groove of the rack stopper is aligned with the notched hole of the rack housing. Install the clip(A) while turning the rack stopper.

CAUTION:
The clip(A) end should not be visible through the notched hole of the rack housing.




9. Install the oil seal and the ball bearing in the valve body(A).




10. After applying the specified fluid and grease to the pinion valve assembly(A), install it in the rack housing assembly.




11. After applying the specified fluid to the oil seal, install it in the rack housing, and fix the valve body assembly(A) and O-ring in the gear box(B).




12. Install the tab washer and the tie rod and stake the tab washer(A) end at two points over the tie rod.

NOTE:
1. Align the tab washer pawls with the rack grooves.
2. Always use a new tab washer.




13. Install the bushing(A), rack support yoke(B), rack support spring(C), lock nut(E) and yoke plug(D) in the order shown in the illustration. Apply semi-drying sealant to the threaded section of the yoke plug before installation.




14. With the rack placed in the center position, attach the yoke plug to the rack housing. Tighten the yoke plug to 15 Nm (150 kg.cm, 11 lb.ft), using a 14 mm socket. Loosen the yoke plug approximately from 30° to60° and tighten the locking nut to the specified torque.

Tightening torque
50 - 70 Nm (500 - 700 kg.cm, 36 - 51 lb.ft)





15. Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.
16. Apply the specified grease to the bellows mounting position (fitting groove) of the tie rod.

Recommended grease: Silicone grease





17. Install the new attaching band to the bellows.

NOTE:
When the bellows are installed, a new band must be used.

18. Install the bellows in position, taking care not to twist it.
19. Fill the dust cover inner side and lip with the specified grease, and fix the dust cover in position with the clip ring attached in the groove of the tie rod end.

Recommended grease
A : POLY LUB GLY 801K or equivalent
B : SHOWA SUNLIGHT MB2 or equivalent
Dust cover inner side and lip : THREE BOND





20. Install the tie rods so that the length of the left and right tie rods equals the standard value.

Standard value
Tie rod free length(A) : 203.6 mm (8 in.)





21. Check for total pinion preload.