Tie-Rod / Rack Boot Removal and Installation

Tie-Rod / Rack Boot Removal and Installation
Reference: Tie-Rod End Removal and Installation:Electric Type
Reference: Steering Gear Case Assembly Components:Electric Type
Reference: Steering Rack Boot Inspection:Electric Type

Removal
1) Remove steering gear case assembly.
2) Remove member bracket from steering gear case assembly.
3) For ease of adjustment after installation, make marking (1) of tie-rod end lock nut position of tie-rod thread.





4) Loosen tie-rod end lock nut and remove tie-rod end.
5) Remove boot band (2) and clip (1).
6) Remove boot from tie-rod.





7) Unbend bent part of tie-rod lock washer (1).
8) Remove tie-rod (3) from rack (2).





Installation
1) Install tie-rod (1) and tie-rod lock washer to rack (2).
2) Hold rack with soft jawed vise and tighten tie-rod to specified torque.

Tightening torque
Tie-rod (a): 75 Nm (7.5 kg-m, 54.5 lbf-ft)





3) Bend lock washer at 2 places (1) as shown in figure.





4) Apply grease "A" to boot inside as shown in figure. Position boot properly in grooves of gear case (or rack side mount) and tie-rod.
After this, check to ensure that boot is free from twist and dent.

"A": Grease 99000-25050 (SUZUKI Super Grease E)





5) Clamp boot with clip and wire. Wire should be new and should go around the boot twice.
Pull its both ends together by screwdriver or such and make sure that the wire won't be crossed. Then twist the ends 4 - 5 times, the twisted ends should be bent in the circumferential direction.

NOTE:
After clamping, make sure that the boot installation part is fixed.
If the boot turns easily by hand, tighten with higher torque to fix it firmly.





6) Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock nut to marking (1) made in removal.

NOTE:
When tie-rod was replaced, measure length "a" on removed tie-rod and use it on new replacement tie-rod so as to position lock nut properly.





7) Tighten tie-rod end lock nut to specified torque.
8) Install member bracket (1), and then install earth cable (2) as shown in figure.

Angle "a"
: Within 20°

Tightening torque
Earth cable bolt (a): 4.0 Nm (0.4 kg-m, 2.8 lbf-ft)