Assembly

1. Apply a suitable oil to entire surface of oil seal for rack.
2. Using oil seal installer tool No. 09573-33000 and guide tool No. 09573-33100, or equivalents, install back-up washer and oil seal in gear housing.
3. Apply suitable lubricant to surface of needle bearing, then using valve stem oil seal installer tool No. 09222-21100, or equivalent, install needle bearing in gear housing. Note direction of needle bearing.
4. Using a front seal installer tool No. 09431-11000, or equivalent, place inscribed side of oil seal in the gear housing.
5. Apply suitable lubricant to rack bushing oil seal surface, then install seal into rack bushing.
6. Insert rack bushing O-ring, then apply a suitable lubricant to rack teeth. Do not plug vent hole in rack with grease.
7. Insert rack into gear housing, then install rack bushing and rack stopper.
8. Push rack stopper until circlip groove is aligned with notched hole in housing, then insert circlip while turning rack stopper, Ensure circlip end is not visible through notched hole of rack housing.
9. Apply suitable lubricant to pinion valve assembly, then install to gear housing.
10. Using valve stem oil seal installer tool No. 09222-21100, or equivalent, install ball bearing, then the pinion and valve assembly to valve housing.
11. Using bearing installer tool No. 09432-21601, or equivalent, install oil seal and snap ring.
12. Rotate pinion fully clockwise, then tighten new self-locking nut.
13. Apply suitable sealant to threaded section of end plug. Tighten to specifications.
14. Stake end plug at two points using a suitable punch, then install new tab washer and tie rod. Peen tab washer end at two points to tie rod.
15. Install bushing, rack support, spring, and rack support cover. Apply suitable lubricant to threaded section of rack support prior to installation.
16. Place rack at center position, then torque rack support cover to 8 ft. lbs. Loosen cover approximately 30-60°, then tighten locknut to specifications.
17. Tighten feed tube, then install mount rubber using a suitable adhesive.
18. Apply suitable lubricant to bellows fitting position of tie rod, then install new attaching band to bellows.
19. Fill inside of dust cover with a suitable lubricant, then place dust cover into position with clip ring attached to groove at tie rod end.

Fig. 4 Tie Rod Installation:

20. Install tie rods until free length of left and right rods are 7.38 inches, Fig. 4.