Removal and Installation

Steering Rack Plunger Removal and Installation

Steering Gear Case Assembly Components:Electric Type

Steering Gear Case Assembly Removal and Installation:Electric Type

Removal

1) Loosen lock nut (1) with holding rack damper screw (2).
2) Remove lock nut (1), rack damper screw (2), rack plunger spring (3), washer (5), spring washers (6), O-ring (7) and rack plunger (4).






Installation

Steering Rack Plunger Inspection:Electric Type
1) Install plunger (1), new O-ring (6), washer (4), spring washers (5) and spring (2) as shown.

NOTE:
Do not wipe off grease previously applied to new plunger.

2) Apply sealant to rack damper screw (3) and tighten them as follows.
a) Tighten rack damper screw to 25 Nm (2.5 kgf-m, 18.5 lbf-ft).
b) Loosen damper screw until 180°.
c) Retighten rack damper screw to 3.9 Nm (0.39 kgf-m, 3.0 lbf-ft).
d) After tightening rack damper screw to specified torque, turn it back by 10° or less.

"A" Water tight sealant: 99000-31250 (SUZUKI Bond No.1207F)

Tightening torque
Rack damper screw (a): (Tighten 25 Nm (2.5 kgf-m, 18.5 lbf-ft) and loosen 180� and then tighten 3.9 Nm (0.39 kgf-m, 3.0 lbf-ft) and turn it back by 10� or less by the specified procedure.)





3) Pinion rotation torque should be checked with rack position centered.

Also, check if rack as a whole moves smoothly.
Special Tool

(A): 09944-18220

Tightening torque
Rotation torque of pinion (a): 2.2 Nm (0.22 kgf-m, 1.5 lbf-ft)





4) After adjustment, tighten lock nut to specified torque with holding damper screw at the position.

Tightening torque
Steering rack damper lock nut 60 Nm (6.0 kgf-m, 43.5 lbf-ft)