Assembly

1. Apply the specified oil, ATF DEXRON II to the entire surface of the rack oil seal.
2. Install the backup washer and oil seal to the specified position in the gear housing.
3. Apply the specified grease, multipurpose grease SAE J310, NLGI No. 2 to the entire surface of the needle bearing.





4. Set the scribed side of the needle bearing in the Special Service Tool (SST) and install it into the gear housing (until the special tool contacts the gear housing).

NOTE: Note the direction of the needle bearing.





5. Apply the specified grease, multipurpose grease SAE J310, NLGI No. 2 to the ball bearing and install using the special tool.

NOTE: Always use a new bearing.

6. Apply the specified oil, ATF DEXRON II to the entire surface of the rack bushing oil seal.
7. Install the oil seal in the rack bushing.





8. Apply the specified oil to the entire surface of the O-ring and install it in the rack bushing.





9. Apply the specified grease, multipurpose grease SAE J310, NLGI No. 2 to the rack teeth.

NOTE: Do not plug the vent hole in the rack with grease.





10. Wrap the rack end with vinyl tape, apply a coating of the specified fluid, and then install the rack bushing and rack stopper.

NOTE: Do not allow oil seal retainer spring to slip out.





11. Push in the rack stopper until the circlip groove of the rack stopper is aligned with the notched hole of the rack housing. Install the circlip while turning the rack stopper.

NOTE: The circlip end should not be visible through the notched hole of the rack housing.





12. Using special tool, install the oil seal and the ball bearing in the valve body.





13. When installing seal rings, press firmly into valve groove. Apply specified fluid.





14. Apply the specified oil, ATF DEXRON II and grease, multipurpose Grease SAE J310, NLGI No.2 to the pinion valve assembly and install in the gear housing assembly.





15. Apply the specified oil and then use the special tool to install the seal in the valve body housing.





16. Install the valve body assembly with the seal ring to the gear box.





17. Install the tab washer and the tie rod and stake the tab washer end at two points over the tie rod.

NOTE:
- Align the tab washer pawls with the rack grooves.
- Always use a new tab washer.





18. With the pinion turned all the way clockwise, tighten the self locking nut.

CAUTION: Always use a new nut.





19. Apply semi-drying sealant to the threaded section of the end plug and tighten to 50-70 Nm (37-52 ft. lbs.).
20. Stake the end plug at two points on its circumference with a punch.





21. Install the bushing, rack support yoke, rack support spring and yoke plug in the order shown. Apply semi-drying sealant to the threaded section of the yoke plug before installation.





22. With the rack placed in the center position, attach the yoke plug to the gear housing. Tighten the yoke plug to 15 Nm (11 ft. lbs.), using the special tool. Loosen the yoke plug approximately 30 to 60°,and tighten the locking nut to 50-70 Nm (37-52 ft. lbs.).
23. Tighten the feed tube to the specified torque and install the mounting rubber using adhesive.





24. Apply the specified grease, Silicone grease to the bellows mounting position (fitting groove) of the tie rod.
25. Install the attaching band to the bellows.

NOTE: When the bellows are installed, a new band must be used.

26. Install the bellows in position, taking care not to twist it.





27. Fill the dust cover inner side and lip with the specified multipurpose grease, and place the dust cover in position with the clip ring attached in the groove of the tie rod end.





28. Screw in the tie rod end to have its right and left length as illustrated, then lock with a lock nut.





29. Push in the power steering gear box assembly from the right side of the vehicle.
30. Install the dust cover mounting plate.
31. Connect the dust cover to its mounting plate with a new strap.





32. Connect the steering gear box assembly to the steering column and shaft assembly.

NOTE: This work should be done by two persons. While one is pushing the gear box assembly toward the steering column and shaft assembly from underside of the vehicle, the other one is connecting the gear box to the steering column and shaft.

33. Remaining installation procedure is the reverse order of removal.
34. After installation, bleed the system.