Assembly

STEERING GEAR AND LINKAGE ASSEMBLY
- Assemble in the order indicated in the table.

Backup Washer Assembly Note
1. Apply ATF to the new oil seal.





2. Install the backup washer and oil seal by using the SSTs.
3. After installing, shake the gear housing and verify that the backup washer does not rattle.
4. If it rattles, remove the oil seal and backup washer, and install them.

Steering Rack Assembly Note
1. Apply ATF to a new O-ring and seal ring.
2. Install the O-ring and seal ring in the piston groove.
3. Apply grease to the friction surface and teeth of the rack.
4. Slide the vinyl sleeve (supplied in the seal kit) over the rack, and slide the rack in from the tube side.





5. Remove the vinyl sleeve.

Oil Seal and O-ring Assembly Note
1. Apply ATF to a new oil seal.
2. Set a plate on the oil seal and press it into the rack bushing until the plate contacts the edge of the rack bushing.
3. Apply ATF to the new O-ring.





4. Install the O-ring onto the groove of the rack bushing.

Rack Bushing Assembly Note
1. Apply ATF to the friction surface of the rack bushing.





2. Slide the SST over the end of the rack and install the trek Shin

Rack Stop Assembly Note





- Using snap-ring pliers, turn the rack stop into the rack housing until the holes of the rack housing and the rack bushing are aligned.

Clip Assembly Note





1. Insert the clip through the holes and turn the rack stop to install it.
2. Perform the hermetic inspection as follows.





1. Connect the SST (adapters) to the cylinder housing.
2. Connect the vacuum pump to the SST (hose)and apply 400 mmHg {15.7 inch Hg} vacuum.
3. Verify that vacuum pressure is maintained for at least 30 seconds. If not, replace the oil seal.

Seal Ring Assembly Note
1. Apply ATE to new seal rings.
2. Install the seal rings onto the pinion shaft component.





3. Pass the pinion shaft component back and forth through the SST until the seal rings are set.
4. Install the oil seal on the gear side of the pinion shaft.

Oil Seal Assembly Note
1. Apply grease to the lip of a new oil seal.





2. Press the oil seal into the valve housing by using the SST.
3. Press the upper bearing in the valve housing by using the SST.

Ball Bearing Assembly Note





- Press the ball bearing into the pinion shaft by using the SST.

Adjusting Cover Assembly Note
1. Apply sealant to the threads of the adjusting cover.





2. Tighten the adjusting cover to 20 - 29 Nm {2.0 - 3.0 kgf.m, 14 - 22 ft. lbs.} by using the SST, and return it 25 - 30.





3. While keeping the adjusting cover from turning, tighten the locknut by using the SST.





4. Measure the pinion preload as follows.
1. Attach the SST and a pull scale to the pinion shaft.
2. Measure the pinion preload. (Center of rack 90)

Pinion preload: 0.5 - 1.3 Nm {5 - 14 kgf.cm, 4 - 12 inch lbs.} max.
Pull scale reading: 5.0 - 13.7 N {0.5 - 1.4 kgf, 1.1 - 3.0 lbs.}

3. If not within the specification, adjust the adjusting cover.

Tie Rod Assembly Note
1. Install the tie rod by using the SST.

Tightening torque: 79 - 98 Nm {8.0 - 10.0 kgf.m, 58 - 72 ft. lbs.}





2. Bend the new washer at the two points by using a punch.

Boot Assembly Note
1. Apply grease to the inner surface of the small end of the boot.





2. Install the boot and the new boot clamp as shown it in the figure.
3. Install the new small boot clamp.
4. Slide the rack fully in and out to verify that the boot is not twisted.

Tie-rod End Boot Assembly Note
1. Wipe away the grease on the ball joint.
2. Put a small amount of grease (lithium-based) into the new boot and set it onto the tie-rod end.





3. Press the boot onto the tie-rod end by using the SST and a press.
4. Wipe away any grease expelled from the dust boot.

Tie-rod End Assembly Note
- Install the tie-rod end so that it is aligned with the reference marks.