Assembly

NOTE: Before reassembling any parts, inspect them and make sure they are clean. Replace worn or damaged parts.

Install New O-ring:

1. Install a new O-ring on the piston with its narrow edge facing out.
2. Coat the piston seal ring guide with power steering fluid, then slide it onto the rack, big end first.

Seal Installation Using Special Tool:

3. Position the new piston seal ring on the special tool, slide it down onto the big end of the tool, then pull it off into the piston groove on top of the 0- ring.

Slide Tool Onto Rack And Over Piston Ring:

4. Coat the piston seal ring and the inside of the special tool with power steering fluid.
Carefully slide the tool onto the rack and over the piston ring, then rotate the tool as you move it up and down to seat the piston ring.

Installing O-rings On Cylinder Cap:

5. Coat new O-ring with power steering fluid and install them on the cylinder cap.
6. Slide the cylinder cap onto the seal retainer and install the snap ring.

Slide Cylinder Cap Onto Seal Retainer:

7. Coat the new O-ring with power steering fluid and install it on the seal retainer.

Installing Bushing On Steering Rack:

8. Grease the sliding surface of the rack bushing B, and install the bushing on the steering rack.

Apply Grease To Seals:

9. Grease the sliding surfaces of the new cylinder end seal and the special tool then place the seal on the special tool with its grooved side facing opposite the slider.

Install Cylinder End Seal:

10. Grease the steering rack, and install the special tool.

Removing Seal Installer From Rack:

11. Separate the special tool from the cylinder end seal, and remove the tool from the rack.

Fitting Seal Retainer:

12. Fit the seal retainer on the steering rack.

Seating End Seal:

13. Push the rack bushing B toward the seal retainer by hand until the cylinder end seal is seated in the retainer. Fit the bushing stopper ring in the groove of the seal retainer securely.

Installing Retainer Washer On Gear Housing:

14. Install the retainer washer on the gear housing.
15. Place the gear housing on the work bench and insert the seal retainer and steering rack into the gear housing.

Pressing Rack Into Cylinder Housing:

16. Coat the inside surface of the cylinder with power steering fluid, slide it over the rack and info the gear housing; press it into the housing until it seats.

Installing Cylinder Spring Over Rack:

17. Install the cylinder spring over the rack, then coat the rack bushing A with the recommended power steering fluid and install it on the spring.
18. Wrap the end of the steering rack with vinyl tape or use the special tool. Coat the tape or tool with grease.

Installing Cylinder End Seal:

19. Coat the inside surface of the cylinder with power steering fluid and install the cylinder end seal with its grooved side facing out.
20. Install the O-ring and back-up ring on the gear housing.

Positioning Cylinder On Gear Housing:

21. Carefully position the cylinder on the gear housing and loosely install with four cylinder bolts.

CAUTION: Be careful not to damage the end seal in the cylinder housing.

22. Remove the vinyl tape or special tool from the steering rack.

Insert Rack Into Cylinder Housing:

23. Insert the steering rack into the cylinder housing. being careful not to damage the steering rack sliding surface.

Tighten Bolts:

24. Tighten the four cylinder bolts.

NOTE: Before tightening the bolts. make sure the mating surfaces of the cylinder and gear housings fit properly by pushing them together; hold them together while tightening the bolts.

Installing Steering Pinion:

25. Install the steering pinion in the pinion holder.

Snap Ring Installation:

26. Install the 28 mm snap ring securely in the pinion holder groove.

NOTE: Install the snap ring with its tapered side facing out.

Pinion Seal Installation:

27. Grease the steering pinion seal, and install it on the gear housing cap using the special tools.

Installing O-ring:

28. Grease the new O-ring and install it in the groove in the gear housing cap.

Protecting Steering Pinion:

29. Wrap the splined area of the steering pinion with vinyl tape and grease the surface of the tape.

Installing Gear Housing Cap:

30. Install the gear housing cap carefully to avoid damaging or distorting the lip of the seal or the seal spring.
31. Remove the vinyl tape.

Tightening Bolts:

32. Tighten the four flange bolts.
33. Install the O-ring on the rack guide screw.
34. Coat the rack guide with grease.

Rack Guide Screw Installation:

35. Install the rack guide, spring and rack guide screw on the gear housing.
36. Install the valve body unit.
37. Tighten the rack guide screw until it compresses the spring and seats against the rack guide, then loosen it.
38. Retighten it to 4 N-m (O-4 kg-m, 2.9 lb-ft), back it off about 2O°+5°-0° and install the locknut on the rack guide screw.

Tighten Lock Nut Screw:

39. Tighten the locknut while holding the rack guide screw with the special tool.

Transfer Hose Clip Installation:

40. Install the transfer hose clip as shown.

Transfer Hose Band Installation:

41. Install the band rubber and transfer hose band; position the band as shown and tighten it.

Installing Boot:

42. Coat the rack end and inside of the boot with the grease. Then install the boot on the rack end.
43. Screw each rack end into the rack while holding the lock washer so its tabs are in the slots in the end of the rack.

NOTE: Install the stopper washer with the chamfered side facing out.

Install Rack End:

44. Tighten the rack end securely, then bend the lock washer back against the flat on the flange as shown.

Boot Installation And Positioning:

45. Install the boots so that the angle of the offset shaft center line is as shown.

Securing Locking Tabs:

46. Install new boot bands on the boot and bend both sets of locking tabs.
47. Lightly tap on the doubled-over portions to reduce their height.

Positioning Boot Clamps:

48. Install the air transfer hose.
49. After assembling, slide the rack right and left to be certain that the boots are not deformed or twisted.