Assembly

NOTE: When using a vise, do not overtighten it.

1. Coat with power steering fluid or molybdenum disulfide lithium base grease.
2. Install oil seal, as follows:
a. Coat a new oil seal lip with power steering fluid.

b. Using Special Service Tool (SST) 09950 - 60010 (09951 - 00240, 09951 - 00430, 09952 - 06010), 09950 - 70010 (09951 - 07360) or equivalents, press in the oil seal.

NOTICE:
^ Make sure to install the oil seal facing the correct direction.
^ Take care that the oil seal does not get reversed as you install it.

3. Install steering rack, as follows:

a. Install SST 09631 - 20102 or equivalent, to the rack.

NOTE: If necessary, scrape the burrs off the rack teeth end and burnish.

b. Coat the SST with power steering fluid.
c. Install the rack into the rack housing.

NOTICE: Be careful not to damage the oil seal lip.

d. Remove the SST.
4. Install oil seal and the spacer, as follows:

a. To prevent oil seal lip damage, wind vinyl tape on the steering rack, and apply power steering fluid.
b. Coat a new oil seal lip with power steering fluid.
c. Install the oil seal by pushing it into the rack housing without tilting.

NOTICE:
^ Make sure to install the oil seal facing the connect direction.
^ Be careful not to damage the oil seal lip.

d. Install the spacer into the rack housing.
5. Install cylinder end stopper, as follows:

a. Using SST 09950 - 60010 (09951 - 00310), 09950 - 70010 (09951 - 07200) or equivalents, and a hammer, drive in the stopper.
b. Using snap ring pliers, install the snap ring to the rack housing.
6. Air tightness test, as follows:

a. Install SST 09631 - 12071 or equivalent, to the rack housing.

NOTICE: Do not install union seats.

b. Apply 53.3 kPa (15.75 inch Hg) of vacuum for about 30 seconds.
c. Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the oil seals.
7. Install control valve assembly, as follows:
a. Coat the teflon rings with power steering fluid.

b. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
c. Install the valve assembly into the valve housing.

NOTICE: Be careful not to damage the teflon rings and oil seal.

8. Install control valve housing with control valve assembly, as follows:
a. Coat a new O-ring with power steering fluid and install it to the housing.
b. Using a (6 mm) hexagon wrench, torque the two bolts.
Torque: 18 Nm (13 ft. lbs.).

9. Install bearing spacer and self-locking nut. Using SST 09616 - 00010 or equivalent, to stop the control valve shaft rotating, torque a new nut.
Torque: 39 Nm (29 ft. lbs.).
10. Install rack housing cap, as follows:
a. Apply sealant to two or three threads of the cap.
Sealant: Part No. 08833 - 00080, THREE BOND 1344 LOCTITE 242 or equivalent.
b. Torque the cap.
Torque: 69 Nm (50 ft. lbs.).
11. Install rack guide seat, rack guide, rack guide spring and rack guide spring cap, as follows:
a. Install the seat to the guide.
b. Apply sealant to two or three threads of the cap.
Sealant: Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent.
c. Temporarily install the cap.
12. Adjust total preload, as follows:
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the right and left hand rack ends.
b. Using a (24 mm) hexagon wrench, torque the rack guide spring cap.
Torque: 25 Nm (18 ft. lbs.).

c. Using a (24 mm) hexagon wrench, return the cap 12°.
d. Using SST 09616 - 00010 or equivalent, turn the control valve shaft right and left one or two times.
e. Using a (24 mm) hexagon wrench, loosen the cap until the rack guide spring is not functioning.

f. Using SST 09616 - 00010 or equivalent, a torque wrench and hexagon wrench (24 mm), tighten the cap until the preload is within the specification.
Preload (turning): 1.O - 1.9 Nm (8.7 - 17.4 inch lbs.).
13. Install rack guide spring cap lock nut, as follows:
a. Apply sealant to two or three threads of the nut.
Sealant: Part No. 08833 - 00080. THREE BOND 1344, LOCTITE 242 or equivalent.

b. Using SST 09922 - 10010 or equivalent, and a (24 mm) hexagon wrench, torque the nut.
Torque: 50 Nm (37 ft.lbs.).

NOTICE: Use SST 09922 - 10010 or equivalent, in the direction shown in the illustration.

NOTE: Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).

c. Recheck total preload.
Preload (turning): 1.0 - 1.9 Nm (8.7 - 17.4 inch lbs.).
d. Remove the RH and LH rack ends.
14. Install dust cover.
15. Install right and left claw washers and rack ends, as follows:
a. Install a new claw washer, and temporarily install the rack end.

NOTE: Align the claws of the washer with the steering rack grooves.

b. Using a (22 mm) spanner to hold the steering rack steady, and using SST 09922 - 10010 or equivalent, torque the rack end.
Torque: 77 Nm (57 ft. lbs.).

NOTICE: Use SST 09922 - 10010 or equivalent in the direction shown in the illustration.

NOTE: Use a torque wrench with a fulcrum length of 380 mm (14.96 inch).

c. Using a brass bar and a hammer, stake the washer.

NOTICE: Avoid any impact to the rack.

16. Install right and left rack boots, clamps and the clips, as follows:

a. Make sure that the steering rack hole is not clogged with grease.

NOTE: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel turned.

b. Install the boot.

NOTICE: Be careful not to damage or twist the boot.

c. Install the clamp and clip to the boot.
17. Install right and left tie rod ends and lock nuts, as follows:
a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
b. After adjusting the toe-in, torque the nut.
Torque: 56 Nm (41 ft. lbs.).
18. Install two turn pressure tubes, as follows:
a. Install the two union seats.

b. Using SST 09633 - 00020 or equivalent, install the tube.
Torque: 24 Nm (18 ft. lbs.).

NOTE:
^ Use a torque wrench with a fulcrum length of 300 mm (11.81 inch).
^ This torque value is effective in case that SST is parallel to a torque wrench.

c. Torque the union bolt over two new gaskets.
Torque: 34 Nm (25 ft. lbs.)