Disassembly and Assembly: Assembly

Apply recommended fluid to O-ring. Put an O-ring into rack Teflon ring.
Heat rack Teflon ring to approximately 40°C (104°F) with a dryer. Assemble it to mounting groove of rack.

Fig 1: Heating Rack Teflon Ring Using Dryer
To fit rack Teflon ring on rack, use rack Teflon ring installation tool (SST) from tooth side. Compress rim of ring with the tool.
Apply recommended grease to rack oil seal. Insert rack oil seal, then insert rack assembly to gear housing assembly.
CAUTION:
- When inserting rack assembly, do not damage retainer sliding part. If it is damaged, replace gear housing assembly.
- When inserting rack assembly, do not damage cylinder inner wall. If it is damaged, it may cause oil leaks. Replace gear housing assembly.
- Attach rack oil seal. Both inner lip and outer lip should face each other.
Fig 2: Identifying Rack Teflon Ring

Fig 3: Identifying Inner And Outer Rack Oil Seal Locations
1. To avoid damaging inner rack oil seal, wrap an OHP sheet [approximately. 70 mm (2.76 in) x 100 mm (3.94 in) around rack tooth. Place oil seal on sheet. Then, pull oil seal along with OHP sheet until they pass the toothed section of rack, then remove it.
  
  Fig 4: Identifying Inner Rack Oil Seal
2. Insert rack oil seal (inner) to piston (rack Teflon ring) position and push retainer to adjust screw side with fingers lightly, and then make rack move in gear housing assembly, install rack oil seal (inner) to fit with gear housing assembly.
  
  Fig 5: Inserting Rack Oil Seal (Inner) To Piston
3. When installing outer rack oil seal, cover the end of rack with an OHP sheet [70 mm (2.76 in) x 100 mm (3.94 in)]. It will avoid damaging rack oil seal. Then place oil seal on sheet. Pull rack oil seal along with OHP sheet until they pass rack end. Then remove OHP sheet.
4. Install end cover assembly to rack, move it to gear housing assembly.
Fig 6: Identifying End Cover Assembly To Rack Edge
Using a 45 mm (1.77 in) open head (suitable tool), tighten end cover assembly at the specified torque.
CAUTION: Do not damage rack surface. If it is damaged, it may cause oil leaks. Replace rack assembly.

Fig 7: Holding Rack Pinion Assembly
After tightening end cover assembly, caulk cylinder at one point as shown in the figure using a punch. This will prevent end cover from getting loose.
Install pinion assembly to gear housing assembly.
CAUTION: In order to protect oil seal from any damage, insert pinion assembly out straightly.
Apply recommended fluid to O-ring. Install O-ring to rear cover.
Use a rear cover wrench (SST), install rear cover to gear housing assembly.

Fig 8: Tightening End Cover Assembly
Confirm projection on rear cover cap nearly fit with marking position on gear housing assembly.
Apply recommended thread locking sealant to the thread (2 turns thread), and then screw in the adjusting screw until it reaches height "H" from gear housing assembly measured before disassembling.
Rotate pinion ten times whole range of rack so that parts get to fit with each other.

Fig 9: Adjusting Screw Height From Gear Housing Assembly
Measure pinion rotating torque within from -180° to +180°, make preload gauge (SST) and torque adapter (SST) in rack neutral position, then hold preload gauge (SST) at maximum torque.
After loosening adjusting screw once, tighten it again with torque of 5.4 N.m (0.55 kg-m, 48 in-lb). After that loosen it within 20° to 40°.

Fig 10: Measuring Pinion Rotating Torque
Measure pinion rotating torque with torque adapter (SST) and preload gauge (SST), then confirm whether it's reading is within the specified value. If the reading is not within the specified value, readjust screw angle with adjusting screw. Change gear assembly to new one, if the reading is still not within the specified value or the rotating torque of adjusting screw is less than 5 N.m (0.51 kg-m, 44 in-lb).

Fig 11: Measuring Pinion Rotating Torque Using Tools

Pinion rotating torque:

Around neutral position (within ±100°)

Average "A":

0.8 - 2.0 N.m (0.08 - 0.20 kg-m, 7 - 18 in-lb)

Other than above (more than ±100°)

Maximum variation "B":

2.3 N.m (0.23 kg-m, 20 in-lb)
Turn pinion fully to the end of the left with inner socket to gear housing assembly.

Set dial gauge to rack as shown in the figure. Measure vertical movement of rack when pinion is turned counterclockwise with torque of 19.6 N.m (2.0 kg-m, 14 ft-lb). Check reading is within the specified value. If reading is outside of the specification, readjust screw angle with adjusting screw. If reading is still outside of specification, or if the rotating torque of adjusting screw is less than 5 N.m (0.51 kg-m, 44 in-lb), replace steering gear assembly.

Fig 12: Setting Dial Gauge To Rack

TORQUE SPECIFICATION

Amount of vertical movement with rack		Less than 0.265 mm (0.01 in)
Measuring point	Axial direction of rack	5 mm (0.2 in) away from end of gear housing
Measuring point	Radius direction of rack	Shaft direction of adjusting screw

Install large-diameter side of boot to gear housing assembly.
Install small-diameter side of boot to the mounting groove of inner socket boot.
Install boot clamp to the small-diameter side of boot.
Install boot clamp to the large-diameter side of boot.

Fig 13: Installing Boot Clamp To Large-Diameter Side Of Boot
1. Tighten large-diameter side of RH/LH boot with boot clamp (stainless wire).
  Wire length "L" : 390 mm (15.35 in)
2. After wrapping clamp around boot groove for two turns, insert screwdriver in loop on both ends of wire. Twist 4 to 4.5 turns while pulling with a force of approx. 98 N (10 kg, 22 lb).
  
  Fig 14: Identifying Dimension Of Boot Clamp
3. Twist boot clamp as shown in the figure, pay attention to relationship between winding and twisting directions.
Fig 15: Identifying Boot Clamp Winding And Twisting Directions
Install cylinder tubes to gear housing assembly.
Install lock nut and outer socket to inner socket.

Fig 16: Caution For Do Not Grip Cylinder With Vise
Tighten lightly inner socket in specified length "L", then tighten lock nut at specified torque. Refer to "DISASSEMBLY AND ASSEMBLY ". Reconfirm if inner socket length is within limit of specified length "L".
Inner socket length "L" : 135.2 mm (5.32 in)

CAUTION: Perform toe-in adjustment after this procedure. Length achieved after toe-in adjustment is not necessary value given here.

Fig 17: Adjusting Inner Socket To Standard Length L