Steering Gear - Assembly

1. Apply the recommended fluid to the working edge of the steering rack oil seal all around its circumference.

Recommended fluid: PSF-3

2. Install the restrictor washer and oil seal into the steering gear housing as shown in the illustration.

3. Apply the recommended fluid to the oil seal of the rack support bushing all around its circumference.

Recommended fluid: PSF-3

4. Install the oil seal onto the rack support bushing.

5. Apply the recommended fluid to the O-ring and install it onto the rack support bushing of the steering gear.

6. Apply the recommended grease to the steering rack teeth.

Recommended grease:

SAE J310, NLGI No. 2 general purpose

Do not fill the steering rack vent hole with grease.

7. Insert the rack into the steering gear housing, then install the rack support bushing and rack stopper.

8. When the holes are aligned, insert the snap ring into the rack stopper hole through the hole in the steering gear housing. Turn the rack stopper and fully secure the snap ring.

After installing the snap ring, its ends must not be visible through the hole in the steering gear housing.

9. Using the special service tool, install the oil seal and ball bearing into the valve housing.

10. Apply the recommended fluid and grease to the drive pinion and valve assembly, then install the drive pinion and valve assembly into the valve housing.

11. Apply the recommended fluid to the oil seal and install it into the steering gear housing.

Install the valve housing assembly and O-ring onto the steering gear housing.

12. Install a new lock washer and steering tie rod.

Stake the edges of the lock washer at two places on the steering tie rod.

1. Bend the two tabs of the lock washer into the grooves of the steering tie rod at two places.

2. Always replace the lock washer with a new one before installation.

13. Install the bushing, rack stopper, rack stopper spring and rack stopper cap into the steering gear housing in the sequence shown in the illustration. Apply semi-drying sealant to the threads of the rack stopper cap before installing it.

14. Set the rack to the center position, then insert the rack stopper cap into the steering gear housing. Using the special service tool, tighten the rack stopper cap to a torque of 15 N·m.

Loosen the rack stopper cap by 30 – 60 degrees, then tighten the rack stopper cap lock nut to the specified torque.

Tightening Torque:

50 - 70 N·m

15. Install and tighten the steering gear tube bracket to the specified torque, then install the rubber mounts in place using the specified adhesive.

16. Apply the recommended grease at the installation point of the small boot clamp on the steering tie rod (into the groove on the rod).

Recommended grease:

Silicone grease

17. Install a new large steering tie rod boot clamp.

Always replace the large boot clamp with a new one before installing the steering tie rod boot.

18. Install the steering tie rod boot in place, making sure it is not twisted.

19. Fill the inside of the tie rod end ball joint boot (A) and the working edge of the ball joint (B) with the recommended grease. Apply the recommended sealant to the sealing edge of the boot and secure it to the ball joint with the clamp.

Recommended grease:

A: POLY LUB GLY 801K or equivalent B: SHOWA SUNLIGHT MB2 or equivalent Recommended sealant:

For boot sealing edge: THREE BOND

20. Screw the left and right steering tie rod ends in so that the protruding length of the rod is the same on both sides and equals the specified value. Secure the position with the lock nut.

Protruding length of steering tie rod:

Specified value: 204.5 mm 21. Check the total rotating torque of the steering gear drive pinion (preload of the steering gear drive pinion shaft).