Assembly
Assembly (2WD & 4WD)
1. Assemble in the order shown in the figure, referring to Assembly Note.
Assembly note
Seal ring, 0-ring
1. Apply ATF to the seal ring and 0-ring.
2. Install the 0-ring in the ring groove of the rack.
3. Install the seal ring in the groove of the rack.
Note: Be careful not to cut or otherwise damage the edge of the seal ring.
4. Compress the seal ring by hand to fit it into the groove.
Needle bearing
1. Apply grease to the end of the SST.
2. Apply ATF to the needle bearing.
3. Set the needle bearing on the SST.
Note: When installing the needle bearing to the SST, install the embossed side first.
4. Insert the needle bearing and the SST into the housing.
5. Set the housing on a press and press in the bearing.
Oil seal
1. Apply grease to the end of the SST.
2. Apply ATF to the oil seal.
3. Set the oil seal on the SST.
4. Insert the oil seal and the SST into the housing.
5. Set the housing on a press and press in the seal.
Spacer, oil seal
1. Set the oil seal on the SST (49 L032 304 and 49 L032 303) as shown.
2. Remove the SST (49 L032 304).
3. Set the oil seal on the rack through the rack teeth with the SST (49 L032 303) as shown.
4. Apply grease to flat surface of the spacer.
5. Set the spacer so that the grease coated surface contacts the oil seal.
6. Apply ATF to the spacer and the oil seal.
7. Insert the rack from the tube side.
Rack bushing assembly
1. Install the rack bushing assembly in the rack housing.
Tightening torque: 108-127 N.m (11-13 m-kg, 80-94 ft-lb)
2. Stake the rack housing at two points approx 1.5mm (0.06 in) from the end with a hammer and center punch.
Hermetic inspection
1. Connect the SST to the cylinder housing.
2. Connect a vacuum pump to the SST.
3. Apply 4OOmmHg (15.7 inHg) vacuum.
4. Verify that vacuum is held for at least 30 sec. If not, check the seal and assembly.
Lower bearing
1. Secure the gear housing in a vise so that the lower bearing bore faces upward.
2. Apply ATF to the lower bearing, then install it in the housing.
3. Press the bearing into the gear housing with the housing cover. Tighten the cover until the tightening force suddenly increases.
Pinion shaft and control valve assembly
1. Apply grease (lithium base, NLGI No.2) to the teeth of the pinion shaft.
2. Apply ATF to the seal ring and the friction surface of the control valve.
3. Install the pinion shaft in the housing.
Note: Be careful not do damage the oil seal by the teeth of the pinion. Be careful not to damage the edge of the seal ring and control valve.
Upper bearing
Apply ATF to the upper bearing, then install it
Oil seal
1. Apply ATF to the oil seal, and fill inside the lip with grease (lithium base, NLGI No.2).
2. Slide the SST over the serrations of the pinion shaft assembly.
3. Slide the oil seal over the SST and position it in the housing.
4. Tap the oil seal in with the SST until the snap ring installation groove in the housing is just visible.
Note: Apply uniform force to the oil seal when installing.
5. Install the snap ring with a snap ring pliers.
Note: Verify that the snap ring is correctly seated in the ring groove of the housing.
Lower bearing locknut
1. Temporarily install the tie-rod on the tube side of the rack.
2. Invert the housing and install the locknut on the pinion shaft. Turn it until the tie-rod contacts the tube.
3. Tighten the locknut.
Tightening torque: 39-49 Nm (4.0-5.0 m-kg, 29-36 ft-lb)
Housing cover
1. Apply thread sealant to the housing cover threads.
2. Install the housing cover.
Tightening torque: 54-69 N.m (5.5-7 m-kg, 40-51 ft-lb)
3. Stake between the rack housing and housing cover at two points with a center punch.
Adjusting cover
1. Set the rack in the center position.
2. Tighten the adjusting cover to 6.9-12 N.m (70-120 cm-kg, 61-104 in-lb), then loosen it.
3. Tighten again to 4.9-6.4 Nm (50-65 m-kg, 43-56 in-lb), and then return it 35°- 45°.
4. Apply thread sealant to the exposed threads of the adjusting cover.
5. Install and tighten the locknut.
Tightening torque: 49-59 N.m (5.0-6.0 m-kg, 36-43 ft-lb)
Tie-rod
1. Secure the rack in a vise.
2. Install the tie-rod onto the rack.
Tightening torque: 118-137 Nm (12-14 m-kg, 87-101 ft-lb)
3. Tap in a new lock pin.
Boot
1. Apply grease to the inner surface of the small end of the boot.
2. Install the boot. Wrap a new wire around the large end of the boot two times and then twist it 4 to 4.5 times. Bend the twisted part toward the mounting bracket.
Note: Be careful not to break the boot wire.
3. Install the spring clamp on the small end of the boot.
Tie-rod end
1. Align with the marks made before disassembly, and tighten the nut.