Assembly
1. Apply the specified fluid, Automatic transmission fluid DEXRON II type to the entire surface of the oil seal and gear housing.
2. Using the Special Service Tools (09555-21000,09573-21000,09573 33000, 09573-33100), install the backup washer and oil seal to the specified position in the gear housing.
3. Apply the specified grease, multipurpose grease SAE J310a, NLGI No. 2 to the entire surface of the needle bearing.
4. Install the needle bearing in the gear housing using the special tool (09222-21100).
5. Set the scribed side of the oil seal (inner) in the special tool (09431-11000) and install the seal in the gear housing.
CAUTION:
- Note the direction of the oil seal.
- Use a new oil seal.
6. Apply the specified fluid, automatic transmission fluid DEXRON II type to the entire surface of the rack bushing oil seal.
7. Install the oil seal on the rack bushing.
8. Apply the specified fluid to the entire surface of the O-ring and install to the rack bushing using the special tool (094311-1000).
9. Apply the specified grease, multipurpose grease SAE J310a, NLGI grade #2 EP to the rack teeth and wrap with vinyl tape.
CAUTION: Do not plug the vent hole in the rack with grease.
10. Insert the rack into the gear housing. Install the rack bushing and rack stopper.
11. Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing and then install the circlip while turning the rack stopper.
CAUTION: Do not plug the vent hole in the rack with grease.
12. Apply the specified fluid, automatic transmission fluid DEXRON II type and grease, multipurpose grease SAE J310a, NLGI Grade #2 EP to the pinion valve assembly and install to the gear housing assembly.
13. Install the ball bearing using special tool (09222-21100).
14. Install the pinion and valve assembly to the valve housing.
15. Install the oil seal using the special tool (09432-21601).
16. Install the snap ring with snap ring plier.
17. With the pinion turned all the way clockwise, tighten the self-locking nut.
CAUTION: Always replace the self-locking nut with a new one.
18. Apply semi-drying sealant to the threaded section of the end plug and tighten to 50-70 Nm (36-51 ft. lbs.).
19. Stake the end plug at two points on its circumference with a punch.
20. Install the tab washer and then the tie rod and peen the tab washer end at two points to the tie rod with a hammer.
CAUTION:
- Align the tab washer pawls with the rack grooves.
- Use a new tab washer.
21. Install the bushing, rack support, rack support spring and rack support cover in the order shown. Apply thread sealant to the threaded section of the rack support cover before installation.
22. With the rack placed at the center position, attach the rack support plug to the gear housing. Tighten the rack support plug within the range of 20-25 Nm (14.5-18 ft. lbs.), using the special tool. Loosen the rack support plug approximately 10° and adjust to the total pinion standard value of 0.6-1.3 Nm (0.4-0.9 ft. lbs.).
23. After adjusting, lock the rack support plug with the lock nut.
NOTE: When it cannot be adjusted within the specified return angle, check rack support plug components or replace
24. Tighten the feed tube to the specified torque and install the mount rubber using adhesive.
25. Apply the specified grease, multipurpose grease SAE J310a, NLGI grade #2 EP to the bellows fitting position (fitting groove) of the tie rod.
26. Install the new attaching band to the bellows.
CAUTION: Whenever the bellows are installed, a new band must be used.
27. Install the bellows, taking care not to twist it.
28. Fill the dust cover inner side and lip with the specified grease, multipurpose grease SAE J310a, NLGI grade #2 EP and fix the dust cover in position with the clip ring attached in the groove of the tie rod end.
29. Install the tie rods so that the free length of the left and right tie rods will be equal to the standard value of 204.6 +/- 1 mm (8.055 +/- 0.04 inch).