Tie-Rod / Rack Boot Removal and Installation: Installation

Install new tie-rod lock washer and tie-rod to rack.
Tighten tie-rod ball nut to specified torque.
Tightening torque

Tie-rod ball nut (a): 85 N.m (8.5 kg-m, 61.5 lb-ft)
Bend lock washer at 3 places (1) as shown.

Fig 1: Installing Tie-Rod Lock Washer And Tie-Rod To Rack
Courtesy of SUZUKI OF AMERICA CORP.
Position boot properly in grooves of gear case (2) and tie-rod (4) and clamp it with wire (1) and clip (3).
Wire should be new and should go around twice and be tightened with its both ends twisted together. The twisted ends should be bent in the circumferential direction.

After this, check to ensure that boot is free from twist and dent.

"A": Grease 99000-25050

"B": Sealant 99000-31120 (for resin)

Fig 2: Positioning Boot In Grooves Of Gear Case
Courtesy of SUZUKI OF AMERICA CORP.
Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock nut to marking (1) made in removal.
NOTE: When tie-rod was replaced, measure length "A" on removed tie-rod and use it on new replacement tie-rod so as to position lock nut properly.

Fig 3: Installing Tie-Rod End Lock Nut And Tie-Rod End To Tie-Rod
Courtesy of SUZUKI OF AMERICA CORP.
Install steering gear box to vehicle referring to P/S GEAR BOX REMOVAL AND INSTALLATION .