Assembly

1. Mounting bracket and rubber:
a. Install mounting rubber.
b. Tap mounting bracket on with plastic hammer.

2. O-ring and seal ring:
a. Apply transmission fluid to O-ring and seal ring.
b. Install O-ring in ring groove of rack.
c. Install seal ring in groove of rack. Be careful not to cut or otherwise damage edge of seal ring.
d. Insert needle bearing and tool No. 49G032313, or equivalent, into housing.
e. Set housing on press and press in bearing.

3. Oil seal:
a. Apply grease to end of tool No. 49G032313, or equivalent.
b. Apply transmission fluid to oil seal, then set seal on tool.
c. Insert oil seal and tool into housing.
d. Set housing on press and press in seal.

4. Spacer and pinion housing side oil seal:
a. Apply grease to flat surface of spacer.
b. Connect oil seal to grease coated surface of spacer.
c. Apply transmission fluid to inside and outside of spacer and oil seal.
d. Set spacer and oil seal on tool No. 49G032310, or equivalent.
e. Insert tool from tube side.
f. Install and tighten nut against tube using tool No. 49G032311, or equivalent.
g. Turn tool shaft in as far as it will go to push in seal and spacer, then remove tool.

5. Rack:
a. Apply lithium base grease to friction surface and teeth of rack.
b. Slide tool No. 49G032305, or equivalent, over rack and slide it in from tube side, then remove tool.

6. Oil seal (rack):
a. Apply transmission fluid to oil seal and slide it on rack.
b. Set tool No. 49G032304, or equivalent, on rack.
c. Turn tool as far as it will go and push oil seal into tube, then remove tool.

7. Rack bushing:
a. Install rack bushing assembly in rack housing, torque to 65 - 72 ft.lb.
b. Stake rack housing at two points, approximately 0.06 inch (1.5 mm) from end, with a hammer and center punch.

8. Hermetic inspection:
a. Connect tool Nos. 49G032317 and 49G032319, or equivalents, to cylinder housing, then connect vacuum pump to tools.
b. Apply 15.7 inches Hg vacuum and ensure vacuum is held for at least 30 seconds. If not, check seal and assembly.

9. Lower bearing:
a. Secure gear housing in vise so that lower bearing bore faces upward.
b. Apply transmission fluid to lower bearing, then install it in housing.
c. Press bearing into gear housing with the housing cover, tightening cover until tightening force suddenly increases.

10. Pinion shaft assembly:
a. Apply lithium base grease to teeth of pinion shaft.
b. Apply transmission oil to seal ring and friction surface of control valve.
c. Install pinion shaft in housing. Be careful not to damage oil seal or edge of seal ring and control valve.

11. Apply transmission fluid to upper bearing, then install it.
12. Oil seal:
a. Apply transmission fluid to oil seal and fill inside lip with lithium base grease.
b. Slide tool No. 49G032309, or equivalent, over serrations of pinion shaft assembly.
c. Slide oil seal over tool and position it in housing.
d. Tap oil seal with tool No. 49G032308, or equivalent, until snap ring installation groove in housing is just visible. Apply uniform force to oil seal when installing.

13. Install snap ring, ensuring it is correctly seated in ring groove.
14. Locknut:
a. Temporarily install tie rod on tube side of rack.
b. Install locknut and turn it until tie rod contacts tube.
c. Torque locknut to 33 - 40 ft.lb.

15. Housing cover:
a. Apply thread sealant to housing cover threads.
b. Install housing cover, torque to 33 - 40 ft.lb.
c. Stake between rack housing and housing cover at two points with a center punch.

16. Pressure pad:
a. Secure gear housing in vise so that pressure pad position faces upward.
b. Apply lithium base grease to rack sliding surface of pressure pad, then install it in housing.
c. Install pressure pad.

17. Adjust cover:
a. Set rack in center position.
b. Torque adjust cover to 7.2 ft.lb., then loosen it.
c. Torque adjust cover to 3.6 - 4.4 ft.lb., then loosen 45°.
d. Apply thread sealant to exposed threads of adjust cover.
e. Install locknut, torque to 36 - 43 ft.lb.

18. Tie rod:
a. Secure rack in vise.
b. Install tie rod on rack, torque to 90 - 105 ft.lb.
c. Tap in a new roll pin.

19. Boot:
a. Apply grease to inner surface of small end of boot.
b. Install boot. Wrap a new wire around large end of boot two times and then twist it 4 or 4 1/2 times. Bend twisted part toward mounting bracket. Be careful not to break boot wire.

20. Align match marks and install tie rod ends.
21. Secure mounting bracket in vise so that oil pipe connections face upward, then install pipes.
22. Install pressure switch O-ring in gear housing, then install oil pressure switch, torque to 23 - 27 ft.lb.