Assembly

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

Second Of Three:

1. Coat the assembly with power steering fluid or molybdenum disulfide lithium base grease.
2. Install the oil seal, performing the following.
a. Coat a new oil seal lip with power steering fluid.





b. Using the 0995-60010 (09951-024O, 09951-00430, 09952-06010), 0995-70010 (09951 - 07360) SST, press in the oil seal.

NOTE:
^ 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 the steering rack by performing the following.
a. Install the 09631-33010 SST 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.

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

d. Remove the SST.
4. Install the bushing, performing the following.
a. Coat a new O-ring with power steering fluid and install it to the bushing.





b. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
c. Install the bushing.

NOTE:
^ Make sure to install the bushing facing the correct direction.
^ Be careful not to damage the oil seal lip.

5. Install the cylinder end stopper by following these procedures.





a. Align the installation hole for the wire of the stopper with the slot of the rack housing.
b. Install a new wire into the stopper.
c. Using the 09631-10021 Special Service Tool (SST), turn the stopper clockwise 450 + 50°.
6. Perform an air tightness test by performing the following.





a. Install the 09631 - 12071 SST to the rack housing.
b. Apply 53 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 the rack housing No.2 bracket and grommet.
a. Install the grommet to the bracket.





NOTE: Align the projection of the grommet with the hole of the bracket.

b. Align the matchmarks on the bracket and rack housing.





c. Place the bracket in a vise and tighten the vise to fasten the clamp.
8. Install the control valve assembly and do the following.





a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the valve shaft.
b. Coat the teflon rings with power steering fluid.
c. Install the valve assembly into the valve housing.

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

9. Install the oil seal, performing the following.
a. Coat a new oil seal lip with power steering fluid.





b. Using the 09612-22011 SST, press in the oil seal.

NOTE: Make sure to install the oil seal facing the correct direction.

10. Install the control valve housing with the control valve assembly and do the following.
a. Place a new gasket on the rack housing.
b. Align the matchmarks on the valve housing and rack housing, and tighten the two bolts to 18 Nm (13 ft. lbs.).





11. Using the 09616 - 00010 SST to stop the control valve shaft rotating, install and tighten a self-locking nut to 25 Nm (18 ft. lbs.).
12. Install the dust cover.
13. Install the rack housing cap and do the following.
a. Apply part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent sealant to 2 or 3 threads of the cap.
b. Tighten the cap to 59 Nm (43 ft. lbs.).





c. Using a punch and hammer, stake the two parts of the cap.

14. Install the rack guide seat, rack guide, rack guide spring and rack guide spring cap by performing the following.
a. Install the seat to the guide.
b. Apply part No.08833-0080, THREE BOND 1344, LOCTITE 242 or equivalent sealant to 2 or 3 threads of the cap.
c. Temporarily install the cap.

15. Adjust the total preload by performing the following.
a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the right and left hand rack ends.





b. Using the 09631-1 0021 SST, tighten the rack guide spring cap to 25 Nm (18 ft. lbs.).





c. Using the 09631 - 10021 SST, return the cap 12°.





d. Using the 09616-00010 SST, turn the control valve shaft right and left 1 or 2 times.
e. Using the 09631-10021 SST, loosen the cap until the rack guide spring is not functioning.





f. Using the 09616 - 00010, 09631-10021 SST and a torque wrench, tighten the cap until the preload is within the specification of 0.8-1.4 Nm (6.9-12.2 inch lbs.).

16. Install the rack guide spring cap lock nut and do the following.
a. Apply part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent sealant to 2 or 3 threads of the nut.





b. Using the 09631 - 10021, 09922-10010 SST, hold the rack guide spring cap, and using the SST tighten the nut to 50 Nm (37 ft. lbs.).

NOTE:
^ Use the 09922-10010 SST in the direction shown in the illustration.
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
c. Recheck the total preload. The Preload (turning) should measure 0.8-1.4 Nm (6.9-12.2 inch lbs.).

d. Remove the right and left hand rack ends.

17. Install the right and left hand claw washers and rack ends by performing the following.





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 (24 mm) spanner to hold the steering rack steady, and using the 09922-10010 SST, tighten the rack end to 60 Nm (45 ft. lbs.).

NOTE:
^ Use the 09922-10010 SST in the direction shown in the illustration.
^ Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).





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

NOTE: Avoid any impact to the rack.

18. Install the right and left hand rack boots, clamps and clips, performing the following.





a. Ensure 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.

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





c. Using the 09521 - 24010 SST, tighten the clamp as shown in the illustration.
19. Install the right and left hand tie rod ends and lock nuts and do the following.
a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
b. After adjusting toe-in, tighten the nut to 74 Nm (54 ft. lbs.).
20. Install the two turn pressure tubes, and do the following.
a. Coat two new O-rings with power steering fluid and install them to the tube.





b. Using the 09633-00020 SST, install the tube, tightening it to 10 Nm (7 ft. lbs.).

NOTE:
^ Use a torque wrench with a fulcrum length of 250 mm (9.84 inch).
^ This torque value is effective in case that SST is parallel to a torque wrench.