Rack Housing Assembly

Using a press, install the bushing to gearbox installation portion.

Fig 1: Installing Bushing To Gearbox Installation Portion Using Press
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Insert the ST to rack.
ST 34199XA010 GUIDE 44

Fig 2: Inserting ST To Rack
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Install the seal ring to piston portion of rack.
Using the ST, form the seal ring properly.
ST1 34199XA020 FORMER PISTON 44

ST2 34199AG060 GUIDE G (26)

Fig 3: Installing Seal Ring To Piston Portion Of Rack
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Using the ST B and ST C, attach the oil seal to ST A.
ST 34199FE040 INSTALLER A, B, C

NOTE: Face the oil seal in the direction as shown in the figure.

Fig 4: Attaching Oil Seal To ST A Using ST B And ST C
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Insert the ST A with oil seal assembled from the gear side of rack. Remove the oil seal from ST A near piston, and then remove the ST A from rack.

Fig 5: Inserting ST A With Oil Seal Assembled From Gear Side Of Rack
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Install the back-up washer from the gear side of rack.

Fig 6: Installing Back-Up Washer From Gear Side Of Rack
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Check the threaded end of holder and gearbox cylinder end for burrs, damage, etc. Correct if faulty.
Apply a coat of grease to the grooves in rack, sliding surface of sleeve and sealing surface of piston. Then insert the rack into steering body from cylinder side.
Attach the ST on gearbox cylinder.
ST 34199XA000 INSTALLER 44
Set the ST to the end of rack.
ST 34199XA030 INSTALLER & REMOVER 44
Using a press, press-fit until the groove of ST1 is aligned to the end surface of ST2.
ST1 34199XA030 INSTALLER & REMOVER 44

ST2 34199XA000 INSTALLER 44

Fig 7: Pressing Until Groove Of ST1 Is Aligned To End Surface Of ST2 Using Press
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Remove the ST.
Insert the outer side oil seal into the rack using the same procedure as steps 5) and 6).
ST 34199FE040 INSTALLER A, B, C
Put the ST and pipe through the rack, and press-fit the outer side oil seal using a press.
ST 34199XA000 INSTALLER 44

Fig 8: Pressing Outer Side Oil Seal Using Press
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Secure the gearbox in a vise using ST.
ST1 926200000 STAND

ST2 34199AG000 BOSS D

Fig 9: Securing Gearbox In Vise Using ST
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Tighten the holder.
Tightening torque: 85 N.m (8.7 kgf-m, 62.7 ft-lb)
Using the ST, crimp so that the diameter of punch hole is 2 - 2.5 mm (0.08 - 0.10 in) and is aligned to the position of 2 mm (0.08 in) from gearbox cylinder end surface.
ST1 34099FA060 PUNCH HOLDER

ST2 34199XA050 BASE

Fig 10: Punching Hole On Gearbox Cylinder End Surface Using ST
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Put a vinyl tape around the spline portion and apply genuine grease to the dust cover and install to valve assembly.
CAUTION: Be sure to install the dust cover to groove of shaft.

Fig 11: Installing Dust Cover To Valve Assembly
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Apply the genuine grease to the pinion gear and bearing of valve assembly.

Fig 12: Applying Genuine Grease To Pinion Gear And Bearing Of Valve Assembly
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Install a new gasket on valve assembly. Insert the valve assembly into place while facing the rack teeth toward pinion.

Fig 13: Installing Valve Assembly
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Tighten the bolts alternately to secure the valve assembly.
Tightening torque: 20 N.m (2.0 kgf-m, 14.8 ft-lb)

CAUTION: Be sure to alternately tighten the bolts.
Temporarily tighten the tie-rod to the rack end, and then operate the rack from lock to lock for two or three times to make it fit in.
CAUTION: Operating the rack from lock to lock without installing tie-rods may damage the oil seal. Always install the left and right tie-rods.
Apply liquid gasket to 1/3 or more of entire perimeter of adjusting screw thread.
Liquid gasket: THREE BOND 1102 or 1215
Apply a coat of grease to the sliding surface of sleeve and seating surface of spring, and then insert the sleeve into steering body.
Charge the adjusting screw with grease, and then insert the spring into adjusting screw. Then install on the steering body.

Fig 14: Applying Coat Of Grease To Sliding Surface Of Sleeve And Seating Surface Of Spring
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Tighten the adjusting screw to the specified torque.
Tightening torque: 5.9 N.m (0.6 kgf-m, 4.4 ft-lb)
Tighten the adjusting screw to the specified torque, then loosen it 20°.
CAUTION: Adjust the adjusting screw with the rack set in a straight-ahead position.
Remove the tie-rod.
Adjust the turning resistance of gearbox so that it is within specification using adjusting screw. Refer to TURNING RESISTANCE OF GEARBOX , INSPECTION, Steering Gearbox.
Attach the lock nut into adjusting screw, and while holding the adjusting screw with wrench, tighten the lock nut using ST.
Liquid gasket: THREE BOND 1102 or 1215

ST 926230000 SPANNER

Tightening torque (lock nut): 25 N.m (2.5 kgf-m, 18.4 ft-lb)

NOTE: Hold the adjusting screw with a wrench to prevent it from turning while tightening lock nut.
Extend the rack approx. 40 mm (1.57 in) from steering body.
Install the tie-rod and new lock washer into rack.
Tightening torque: 128 N.m (13.1 kgf-m, 94.4 ft-lb)

Fig 15: Installing Tie-Rod And New Lock Washer Into Rack
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Bend the lock washer and crimp it.
CAUTION: Be careful not to scratch the rack when crimping lock washer.

Fig 16: Bending Lock Washer And Crimp It
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Apply a coat of grease to the tie-rod groove, and then install the boot to the housing.
CAUTION: Do not confuse the left and right boot when installing as the shape is different.

NOTE: Make sure that the boot is installed without unusual inflation or deflation.

Fig 17: Applying Coat Of Grease To Tie-Rod Groove
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Install a new boot band. Using band clamp pliers, crimp it so that the clearance of crimping portion becomes 2 mm (0.079 in) or less.

Fig 18: Identifying Boot Band Crimping Portion Clearance
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Fix the boot end with small clip.

Fig 19: Fixing Boot End With Small Clip
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After installing, check that the boot end is installed to the groove of the tie-rod.
If the tie-rod end has been removed, screw in lock nut and tie-rod end to the screwed portion of tie-rod, and tighten the lock nut temporarily in a position as shown in the figure.
Installed tie-rod length L: 28 mm (1.1 in)

Fig 20: Identifying Installed Tie-Rod Length (L)
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Inspect the gearbox as follows:
"A" Holding the tie-rod end, repeat lock to lock several times as quickly as possible.

"B" Holding the tie-rod end, turn it slowly at a radius several times as large as possible.

Finally, make sure that the boot is installed in the specified position without inflating.

Fig 21: Inspecting Gearbox
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Remove the gearbox from ST.
ST1 926200000 STAND

ST2 34199AG000 BOSS D
Install the four pipes on gearbox.
1. Connect the pipes A and B to the four pipe joints of gearbox.
  Tightening torque:
  
  Refer to the component parts. Refer to POWER ASSISTED SYSTEM , COMPONENT, General Description.
2. Connect the pipes C and D to gearbox.
Tightening torque:

Pipe C: 37 N.m (3.8 kgf-m, 27.3 ft-lb)

Pipe D: 29 N.m (3.0 kgf-m, 21.4 ft-lb)

Fig 22: Identifying Pipes C And D Of Gearbox
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