Power Steering Gear And Linkage: Assembly

Using a heat gun, heat new teflon rack seal ring to approximately 40°C (104°F). Then place it onto rack.

Fig 1: Heating Teflon Rack Seal Ring
- Using Tool, compress rack seal ring securely on rack.
Always insert the tool from the rack gear side.

Fig 2: Compressing Rack Seal Ring
Insert rack oil seal.
- Place plastic film into rack oil seal to prevent damage by rack teeth.
- Always remove plastic film after rack oil seal is positioned properly.
- Make sure lips of rack oil seal face each other.
  
  Fig 3: Inserting Rack Oil Seal
Install center bushing and rack oil seal with rack assembly.

Fig 4: Installing Center Bushing And Rack Oil Seal
Insert rack oil seal and end cover assembly to rack then tighten end cover assembly.

Fig 5: Inserting Rack Oil Seal And End Cover Assembly
Fasten cylinder end cover assembly to gear housing by staking.

Fig 6: Fastening Cylinder End Cover Assembly
Set rack gear in neutral position.
Rack Stroke "S": Refer to SERVICE DATA AND SPECIFICATIONS (SDS) .

Fig 7: Setting Rack Gear In Neutral Position
Coat seal lip of new pinion oil seal with multi-purpose grease. Install it into pinion housing of gear with a suitable tool.
- Make sure lip of oil seal faces up when installed.
Install pinion bearing adjusting shim(s).
- Whenever pinion assembly, gear housing and rear housing are disassembled, replace shim(s) with new ones. Always use the same number of shim(s) when replacing.
Install pinion seal ring on pinion gear assembly.
- Using a heat gun, heat pinion seal ring to approximately 40°C (104°F) before installing it onto pinion gear assembly.
- Make sure pinion seal ring is properly settled in valve groove.
Apply a coat of multi-purpose grease to needle bearing roller and oil seal lip.

Fig 11: Needle Bearing Roller
Install pinion assembly to pinion housing.
Be careful not to damage pinion oil seal.

Fig 12: Installing Pinion Assembly To Pinion Housing
Apply a coat of multi-purpose grease to rear oil seal lip before installing rear housing.

Fig 13: Rear Housing
Ensure that the rack is centered. Install rear cover cap so that protrusion of rear housing cover is positioned as shown in figure.
Be careful not to damage worm ring and oil seal.

Fig 14: Positioning Rack
Install solenoid valve.

Fig 15: Solenoid Valve
Install diaphragm spring at retainer.
- Always install retainer, spring washer and diaphragm spring in that order.
- Make sure convex end (painted white) of diaphragm spring faces outward when installing.
Install retainer spring and adjusting screw temporarily.

Fig 16: Diaphragm Spring At Retainer

CAUTION: Ensure steering gear spacer is installed with rubber side facing rack.
- Attach lock plate (2) to side rod inner socket (1).
- Insert steering gear spacer (5) to rack (4).
- Apply locking sealant to inner socket threads (3).
  Screw inner socket into rack (4) and tighten to specified torque.
- Stake lock plate at two places.
  
  Fig 17: Staking Lock Plate At Two Places
Install steering gear spacer (5) to lock plate (2).

Fig 18: Steering Gear Spacer To Lock Plate
Tighten outer socket lock nut.
Tie-Rod Length "L": Refer to SERVICE DATA AND SPECIFICATIONS (SDS) .

Fig 19: Measuring Tie-Rod Length
Measure rack stroke.
Rack Stroke "S": Refer to SERVICE DATA AND SPECIFICATIONS (SDS) .

Fig 20: Measuring Rack Stroke
Before installing boot, coat the contact surfaces between boot and tie-rod with grease.

Fig 21: Coating Contact Surfaces Between Boot And Tie-Rod With Grease
Install boot clamps.
- To install, wrap boot clamp around boot groove twice. To tighten clamp, place a screwdriver through both rings. Twist rings 4 to 4-1/2 turns while pulling with a force of approx. 98 N (10 kg, 22 lb).
- Install boot clamp so that it is to the rear of the vehicle when gear housing is attached to the body. (This will prevent interference with other parts.)
- Twist boot clamp in the direction shown in Fig 24.
- After twisting boot clamp, bend twisted and diagonally so it does not contact boot.