Assembly

1. Install O-ring and seal ring in groove on steering rack. Press into place by hand.
2. Apply grease to end of bearing installation tool No. 49 E032 303 or equivalent, place needle bearing on tool and press bearing into housing.
3. Apply grease to end of seal installation tool No. 49 E032 304 or equivalent, place oil seal on tool and press seal into housing.
4. Apply grease to spacer connect a new seal to grease coated surface of spacer.
5. Set spacer and oil seal on seal installation tool No. 49 G032 310 or equivalent and install from the tube side of housing.
6. Apply lithium base grease to friction surface and teeth of steering rack.
7. Slide seal protector tool No. 49 G032 305 or equivalent over end of rack then install rack into housing.
8. Install rack oil seal using installation tool No. 49 E032 301 or equivalent.
9. Perform air tightness check as follows:
a. Install adapter and vacuum tool Nos. 49 G032 319 and 49 B032 317 or equivalent to cylinder of gear housing.
b. Apply 17.7 inches of vacuum and ensure vacuum is maintained for 30 seconds.
c. If vacuum does not hold, replace oil seal.
10. Secure gear housing in a suitable vise with lower bore facing upward.
11. Apply ATF to lower bearing then install it in gear housing using gear housing cover.
12. Apply grease to teeth of pinion shaft, then apply ATF to seal ring and friction surface of control valve.
13. Install pinion shaft into housing.
14. Apply ATF to upper bearing and install it into housing.
15. Apply ATF to oil seal and fill inside lip with grease.
16. Slide seal protector tool over pinion shaft and install oil seal using seal installation tool No. 49 G032 308 or equivalent.
17. Temporarily install tie rod on tube side of rack.
18. Invert housing and install locknut on pinion shaft and tighten to specification.
19. Apply thread sealant to housing cover prior to installation.
20. Stake cover at two points.
21. Support rack in a vise with support yoke faces upward.
22. Apply grease to rack sliding surface of pressure pad then install into housing.
23. Install support yoke and spring.
24. Adjust adjusting cover as follows:
a. Aet rack in center position.
b. Apply sealant to adjuster cover.
c. Using dial indicator tool Nos. 49 H032 321A and 49 D032 316 and a torque wrench, torque adjusting cover to 87 inch lbs, then loosen it.
d. Tighten to 39-48 inch lbs. then loosen it 45°.
e. Measure pinion starting torque using a suitable spring scale and lever tool No. 49 0180 510B or equivalent. Starting torque should be 8.7-10.4 inch lbs. at the neutral position ±90° and 14.7 inch lbs. at other positions.
f. If specification is not as specified repeat step c through e.