Assembly

TOOL REQUIRED
^ ST 926200000 Stand
^ ST 926390001 Cover & Remover
^ ST 1 926400000 Guide
^ ST2 927660000 Guide
^ ST 926340001 Wrench

1. Rack Assembly





a. Fixing rack housing Fix rack housing in vice using ST.

CAUTION:
^ When fixing rack housing in vice, be sure to use this special tool. Do not fix rack housing in vice using pad such as aluminum plates, etc.
^ When using old rack housing, be sure to clean and remove rust before assembling. Check pinion housing bushing carefully.





b. Fit ST over toothed portion of rack assembly, and check for binding or unsmooth insertion. If any deformation is noted on flats at the end of rack, shape by using file, and wash with cleaning fluid.
c. Apply genuine grease to teeth of thoroughly washed rack assembly, and fit ST over the toothed portion.

NOTE:
^ Be careful not to block air passage with grease. Remove excessive grease.
^ After fitting cover, check air passage hole for clogging. If clogged, open by removing grease from the hole.
^ Check rack shaft for damage.
^ Apply ATF DEXRON II to this ST and surface of piston ring to prevent seal from being damaged.





d. Insert rack assembly into rack housing from cylinder side, and remove ST after it has passed completely through oil seal.

NOTE: Before inserting rack assembly, apply a coat of ATF DEXRON II to surfaces of ST and rack piston.






e. Fit ST1 and ST2 over the end of rack, and install rack bushing.

CAUTION:
^ If burrs, or nicks are found on this guide and rack shaft portion, remove by filing.
^ Dip rack bushing in ATF DEXRON II before installing, and pay attention not to damage O-ring and oil seal.





f. Insert rack stopper into cylinder tube until internal groove (on cylinder side) is aligned with external groove (on rack stopper). Turn rack stopper with ST so that rack stopper hole is seen through cylinder slits.
g. Insert rack stopper into rack housing, and wrap circlip using ST to secure rack stopper in position.

CAUTION: Be careful not to scratch rack while winding circlip.

NOTE: Rotate wrench another 90 to 180° after the end of circlip has been wrapped in.

h. Fit mounting rubber onto rack housing.

2. Valve Assembly





a. Apply genuine grease to pinion gear and bearing of valve assembly.





b. Install packing on valve assembly. Insert valve assembly into place while facing rack teeth toward pinion.

CAUTION: Be sure to use a new packing.

NOTE: Do not allow packing to be caught when installing valve assembly.

c. Tighten bolts alternately to secure valve assembly. Tightening torque: 25 ± 5 Nm (18.1 ± 3.6 ft. lbs.).

CAUTION: Be sure to alternately tighten bolts.