Reassembly

POWER STEERING: RACK AND PINION POWER STEERING GEAR: REASSEMBLY

REASSEMBLY

1. INSPECT POWER STEERING RACK

(a) Using a dial indicator, check for runout of the steering rack and teeth wear.
Maximum runout:
0.3 mm (0.0118 in.)
If runout exceeds the maximum, replace the power steering gear assembly.
(b) Check the rack surface for wear and damage.
If necessary, replace the power steering gear assembly.
2. INSTALL POWER PISTON OIL SEAL

(a) Coat a new O-ring with power steering fluid and install it to the steering rack.
(b) Expand a new oil seal with your fingers.

NOTE: Be careful not to overly expand the oil seal.

(c) Coat the oil seal with power steering fluid.

(d) Install the oil seal to the steering rack, and adjust with your fingers.
3. INSTALL POWER STEERING CYLINDER TUBE OIL SEAL

(a) Coat a new cylinder tube oil seal lip with power steering fluid.
(b) Using SST and a press, install the cylinder tube oil seal.
SST: 09950-60010
09951-00420
09951-00250
09952-06010
SST: 09950-70010
09951-07360
4. INSTALL POWER STEERING RACK

(a) Apply grease to the rack teeth ends.
(b) Affix SST to the steering rack.
SST: 09631-33010

HINT: If necessary, scrape the burrs off the rack teeth ends and burnish.

(c) Coat SST and the power piston oil seal with power steering fluid.
(d) Install the steering rack to the rack housing.
(e) Remove SST.
5. INSTALL POWER STEERING RACK BUSH

(a) Coat a new rack bush oil seal lip with power steering fluid.
(b) Using SST and a press, install the rack bush oil seal to the rack bush.
SST: 09950-60010
09951-00400
SST: 09950-70010
09951-07100

NOTE: Make sure that the oil seal is installed correctly.

(c) Coat a new O-ring with power steering fluid and install it to the rack bush.

(d) Install the rack bush to the rack housing.

HINT: Wrap vinyl tape around the end of the steering rack in order to prevent damaging the rack bush oil seal.

6. INSTALL CYLINDER END STOPPER

(a) Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing.
(b) Install a new wire into the cylinder end stopper.
(c) Using a screwdriver, turn the cylinder end stopper counterclockwise by 450°+-50°.
7. AIR TIGHTNESS TEST

(a) Install SST to the rack housing.
SST: 09631-12071
(b) Apply a vacuum of 53 kPa (398 mmHg, 15.65 in. Hg) for approximately 30 seconds.
(c) Check that there is no change in the vacuum pressure.
If there is a change in the vacuum pressure, check the installation of the oil seals.
8. INSTALL POWER STEERING CONTROL VALVE OIL SEAL

(a) Coat the control valve upper bearing with grease.
(b) Coat a new control valve oil seal lip with power steering fluid.
(c) Using SST and a press, install the control valve oil seal.
SST: 09950-70010
09951-07150
SST: 09950-60010
09951-00180
09952-06010
09951-00320

NOTE: Make sure that the oil seal is installed in the correct direction.

(d) Using SST and a press, install the control valve upper bearing.
SST: 09950-70010
09951-07150
SST: 09950-60010
09951-00180
09952-06010
09951-00340
9. INSTALL POWER STEERING CONTROL VALVE

(a) Expand 4 new valve spacers with your fingers.

NOTE: Be careful not to overly expand the valve spacers.

(b) Coat the 4 valve spacers with power steering fluid.
(c) Install the 4 valve spacers to the control valve, and adjust with your fingers.

(d) Carefully slide the tapered end of SST over the valve spacers until they fit to the control valve.
SST: 09631-20081

NOTE: Be careful not to damage the valve spacers.

(e) Install the control valve into the valve housing.

NOTE: Be careful not to damage the valve spacers and the oil seal lip.

HINT: Wrap vinyl tape around the serrated part of the control valve in order to prevent damaging the oil seal.

(f) Coat a new oil seal lip with power steering fluid.
(g) Using SST and a press, install the oil seal.
SST: 09612-22011

NOTE: Make sure that the oil seal is installed in the correct direction.

(h) Apply grease to the needle roller bearing of the rack housing and the serrated part of the control valve.
(i) Install a new gasket to the control valve housing.

(j) Install the control valve housing together with the control valve to the rack housing with the 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)

(k) Using SST, hold the control valve from rotating and install a new lock nut.
SST: 09616-00011
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)
(l) Apply sealant to 2 or 3 threads of the rack housing cap.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

(m) Using a socket wrench (27 mm), install the rack housing cap.
Torque: 54 Nm (546 kgf-cm, 40 ft-lbf)

(n) Using a punch and a hammer, stake the rack housing cap and the rack housing.
10. INSTALL RACK GUIDE
(a) Apply grease to the contact surface of the rack guide.
(b) Install the rack guide and the compression spring.
(c) Apply sealant to 2 or 3 threads of the rack guide spring cap.
Sealant:
Part No. 08833-00080, THREE BOND 1344. LOCTITE 242 or equivalent
(d) Temporarily install the rack guide spring cap.
11. ADJUST TOTAL PRELOAD

(a) Temporarily install the RH and the LH rack end sub-assembly, in order to prevent the oil seal from being damaged by the rack teeth.
(b) Using SST, tighten the rack guide spring cap.
SST: 09631-10021
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)

(d) Using SST, turn the control valve left and right 1 or 2 times.
SST: 09616-00011
(e) Using SST, loosen the rack guide spring cap until the compression spring stops functioning.
SST: 09631-10021

(f) Using SST and a torque wrench, tighten the rack guide spring cap until the preload falls within the specified range.
Preload (turning):
1.2 to 1.5 N*m (12.2 to 15.3 kgf*cm, 10.6 to 13.3 in.*lbf)
SST: 09616-00011
SST: 09631-10021
(g) Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.
Sealant:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
(h) Temporarily install the rack guide spring cap lock nut.

(i) Using SST, hold the rack guide spring cap and using another SST, tighten the spring cap lock nut.
SST: 09616-00011
SST: 09922-10010
Torque: 48 Nm (487 kgf-cm, 35 ft-lbf)

NOTE:
- Use SST 09922-10010 in the direction shown in the illustration.
- Use a torque wrench with a fulcrum length of 345 mm (13.58 in).

(j) Recheck the total preload.
Preload (turning):
1.2 to 1.5 N*m (12.2 to 15.3 kgf*cm, 10.6 to 13.3 in.*lbf)
(k) Remove the RH and the LH rack end sub-assembly.

(l) Apply MP grease around the control valve shaft, as shown in the illustration.

(m) Wrap vinyl tape around the spline of the control valve.
(n) Install the dust cover to the control valve housing.
12. INSTALL STEERING RACK END SUB-ASSEMBLY

(a) Install 2 new claw washers, and temporarily install the LH and the RH steering rack end sub-assembly.

HINT: Align the claws of the claw washer with the steering rack grooves.

(b) Using SST, install the 2 steering rack end sub-assembly.
SST: 09922-10010
Torque: 60 Nm (616 kgf-cm, 45 ft-lbf)

NOTICE:
- Use SST (09922-10010) in the direction shown in the illustration.
- Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).

HINT: Using SST, hold the rack and install the steering rack end sub-assembly.

(c) Using a brass bar and a hammer, stake the 2 claw washers.

NOTE: Avoid any impact to the steering rack.

13. INSPECT POWER STEERING RACK

(a) Ensure that the holes of the steering rack ends are not clogged with grease.

HINT: If the holes are clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.

14. INSTALL STEERING RACK BOOT NO.2

(a) Apply silicon grease to the inside of the small opening of the rack boot No.2.
(b) Install the rack boot No.2 to the groove on the rack housing.

NOTE: Be careful not to damage or twist the boot.

15. INSTALL STEERING RACK BOOT NO.1

HINT: Perform the same procedure as for the rack boot No.2.

16. INSTALL STEERING RACK BOOT NO.2 CLAMP

(a) Using SST, tighten the rack boot No.2 clamp, as shown in the illustration.
SST: 09521-24010
Clearance:
2.0 mm (0.079 in.) or less

NOTE: Be careful not to damage the boot.

17. INSTALL STEERING RACK BOOT NO.1 CLAMP
SST: 09521-24010

HINT: Perform the same procedure as for the No.2 clamp.

18. INSTALL STEERING RACK BOOT CLIP
(a) Using pliers, install the 2 boot clips.
19. INSTALL TIE ROD ASSEMBLY LH

(a) Screw the lock nut and the tie rod assembly LH to the rack end until the matchmarks are aligned.

HINT: After adjusting toe-in, tighten the lock nut.

20. INSTALL TIE ROD ASSEMBLY RH

HINT: Perform the same procedure as for the LH side.

21. INSTALL STEERING LEFT TURN PRESSURE TUBE

(a) Coat 2 new O-rings with power steering fluid and install them to the left turn pressure tube.
(b) Using SST, install the left turn pressure tube to the power steering gear assembly.
SST: 09023-38201
Torque: 11 Nm (113 kgf-cm, 8 ft-lbf)

NOTE: Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

HINT: This torque value is effective when SST is parallel to the torque wrench.

22. INSTALL STEERING RIGHT TURN PRESSURE TUBE

(a) Coat 2 new O-rings with power steering fluid and install them to the right turn pressure tube.
(b) Using SST, install the right turn pressure tube to the power steering gear assembly.
SST: 09023-38201
Torque: 11 Nm (113 kgf-cm, 8 ft-lbf)

NOTE: Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

HINT: This torque value is effective when SST is parallel to the torque wrench.

23. INSTALL POWER STEERING RACK HOUSING HEAT INSULATOR

(a) Install the power steering rack housing heat insulator.

NOTE: Be careful not to damage the heat insulator.