Installation

1. Slide the rack all the way to the right.
2. Pass the right side of the steering gearbox assembly above and through the right side of the rear beam.
3. Raise the left side of the steering gearbox assembly above and through the left side of the rear beam.

Installing Rack Assembly:

4. Insert the pinion shaft up through the bulkhead.

Installing Steering Rack Clamps:

5. Install the holder with arrow mark facing forward and tighten the gearbox mounting bolts.

Connecting Pipes And Fittings:

6. Connect the four lines to the valve body unit, using flare nut wrenches.

A: From pump: 14mm wrench 38 N-m, 3.8 kg-m, 28 lb-ft
B: To oil cooler: 12mm wrench 13 Nm, 1.3 kg-m, 9 lb-ft
C: To reservoir: 17mm wrench 29 Nm, 2.9 kg-m, 21 lb-ft
D: To power steering speed sensor: 12mm wrench 13 Nm 1.3 kg-m, 9 lb-ft

Installing Exhaust "A" Pipe:

7. Install the exhaust pipe A with a new gasket, then tighten the new self-locking nuts and bolts.

Pipe Bracket And HO2S Connector Installation:

8. Install the pipe bracket.
9. Connect the 4P connector to the heated oxygen sensor. (EX, SE only)

Connect Tie Rod Ends:

10. Reconnect the tie-rod ends to the steering knuckles, tighten the castle nut to the specified torque, and install new cotter pins.

CAUTION: Before tightening the steering joint bolts, pull up the steering joint to make sure that the steering joint is fully seated. Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the pin hole. Do not align the nut by loosening.

Checking Cable Reel Centering:

11. Center the steering rack with its strokes.
12. Make sure that the cable reel of the airbag system is centered as follows:

^ Turn the steering wheel left approx. 150 degrees, and check that the cable reel is in position with the indicator.
^ If the cable reel is centered, the yellow gear tooth lines up with the alignment mark on the cover.
^ Return the steering wheel right approx. 150 degrees to position the steering wheel to the straight ahead position.

Steering Joint Installation:

13. Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole with the groove around the shaft) and loosely install the lower bolt.

NOTE:
^ Connect the steering shaft and pinion with the cable reel and steering rack centered.
^ Be sure that the lower steering Joint bolt is securely in the groove on the steering gearbox pinion.

14. Adjust the front toe.

NOTE: If the steering wheel and rack are not centered, reposition the serrations at lower end side of the steering joint.

Steering Joint Cover Installation:

15. Install the steering joint cover with the clamps and clips.
16. Fill the system:

^ Fill the reservoir with new power steering fluid.
^ Start the engine and let it run at idle, then turn the steering wheel from lock-to-lock several times to bleed air from the system.
^ Check the fluid again, and add more if necessary.

Gearbox Shield Installation:

17. Check the gearbox for leaks, then reinstall the gearbox shield.
18. Reinstall the front wheels.