Installation

CAUTION: Be careful not to bend or damage the feed line and cylinder lines when installing the gearbox.

1. Select the 32 mm shim(s).

NOTE: Only reinstall the original 32 mm shim(s) when the steering gearbox is reassembled without replacing the pinion shaft, valve housing, and gearbox housing with new ones. If the pinion shaft, valve housing, and gearbox housing are replaced, select the new shim(s) as follows.

Shim Selection:
a. Set the four 32 mm shims on the bearing surface of the gearbox housing. Total thickness of the four shims should equal no more than 0.70 mm. Shim set: four 32 mm shims (Thickness: 0.10 mm, 0.15 mm, 0.20 mm, 0.25 mm respectively)

CAUTION: The four 32 mm shims do not have thickness identification marks. Measure the thickness of each shim using a micrometer, and mark the shim for identification.





b. Install the valve body unit on the gearbox, and tighten the flange bolts to the specified torque.





c. Measure the clearance between the gearbox and valve body unit using a feeler gauge as shown.

NOTE: Measure the clearance at the point midway between the two mounting bolts.

d. Determine the required thickness-of the 32 mm shims by subtracting the clearance obtained in the step "c" from the total thickness of the four shims. (Total thickness of the 4 shims) - (Clearance) = Required thickness of the shims

NOTE: Select the shims so that the total thickness is close to, but less than, the required thickness. Example: Measurement is 0.28 mm (0.011 inch): 0.70 - 0.28 = 0.42 mm (0.028 - 0.011 = 0.017 inch). The selected shims should be 0.25 mm (0.010 inch) and 0.15 mm (0.006 inch) in thickness. If the required shim thickness is 0.10 mm or less, no shims are necessary.





2. Set the selected 32 mm shims on the bearing surface of the gearbox housing.
3. Coat the new O-ring with grease, and carefully fit it on the valve housing.
4. Apply grease to the needle bearing in the gearbox housing.
5. Install the valve body unit on the gearbox housing by engaging the gears.

NOTE: Note the valve body unit installation position (direction of line connection).

6. Tighten the flange bolts to the specified torque.





7. Install the cylinder lines A and B.

8. Before installing the gearbox, slide the rack ail the way to right.
9. Install the mounting cushion on the steering gearbox.





10. Install the pinion shaft grommet, then insert the pinion shaft up through the bulkhead.

NOTE: Align the notch in the pinion shaft grommet with the tab on the valve housing.





11. Install the mounting bracket over the mounting cushion, then install two gearbox mounting bolts.





12. Install the stiffener plate with the two gearbox mounting bolts arid stiffener plate attaching bolts.

CAUTION: Be sure the air tube is not caught or pinched by stiffener plate.

NOTE: Install the bolts loosely first, then tighten them securely.

13. Install the return hose joint by tightening the 16 mm flare nut.
14. Connect the return hose securely, and tighten the adjustable hose clamp from the engine compartment.





15. Connect the feed line and tighten the 14 mm flare nut.

NOTE: Make sure that there is no interference between the fluid lines, the rear beam or any other parts.

16. Center the steering rack within its stroke.





17. Slip the lower end of the steering joint onto the pinion shaft (line up the bolt hole with the groove around the shaft), and tighten the lower bolt.

NOTE:
- Connect the steering shaft and pinion with the cable reel and steering rack centered.
- Be sure that the lower steering joint bolt is securely in the groove in the steering gearbox pinion.
- If the steering wheel and rack are not centered, reposition the serrations at lower end of the steering joint.

18. Center the cable reel by first rotating it clockwise until it stops. Then rotate it counterclockwise (approximately two turns) until the arrow mark on the label points straight up. Reinstall the steering wheel.





19. Install the steering joint cover with the clamps and a clip.





20. Reconnect the tie-rod ends to the steering knuckles, tighten the castle nut to the specified torque, and install new cotter pins.

NOTE: Before connecting the tie-rod ends, wipe off any grease contamination from the ball joint tapered section and threads.

CAUTION: Torque the castle nut to the lower torque specification, then tighten it only far enough to align the slot with the pin hole. Do not align the nut by loosening.

21. Install the exhaust pipe A or TWC.
22. Connect the shift linkage.
23. Install the front wheels.
24. Fill the system with power steering fluid, and bleed air from the system.
25. After installation, perform the following checks.
a. Start the engine, allow it to idle, and turn the steering wheel from lock-to-lock several times to warm up the fluid. Check the gearbox for leaks.
b. Adjust the front toe. Alignment
c. Check the steering wheel spoke angle. Adjust by turning the right and left tie-rods, if necessary.

NOTE: Turn the right and left tie-rods equally.