Disassembly and Assembly: Assembly

1. Attach lock plate to rack part of gear housing assembly.
   CAUTION: Never reuse the lock plate.
2. Apply thread sealant into the thread of inner socket.

   Use Genuine Medium Strength Thread Locking Sealant or equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

3. Screw inner socket into rack part and tighten at the specified torque.
4. Secure with lock plate.

Rack stroke neutral position (L): Refer to  "RACK STROKE ".

Fig 1: Identifying Rack Stroke Neutral Position

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Use Genuine High Performance Thread Sealant or equivalent. Refer to  "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".

Fig 2: Identifying Adjusting Screw Height

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1. Measure pinion rotating torque within ±180° of neutral position of the rack assembly using Tools. Stop the gear at the point where highest torque is read.

   A: Preload gauge [SST: ST3127S000 (J-25765-A)] 

   B: Preload adapter [SST: KV48103400 (-)] 

   Fig 3: Adjusting Pinion Rotating Torque Using Tools

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2. Loosen adjusting screw and retighten to 5.4 N.m (0.55 kg-m, 48 in-lb), and then loosen by 20 to 40°.
3. Measure pinion rotating torque using Tools to make sure that the measured value is within the standard. Readjust if the value is outside the standard. Replace steering gear assembly if the value is outside the standard after readjusting or adjusting screw rotating torque is 5 N.m (0.51 kg-m, 44 in-lb) or less.

   Pinion rotating torque 

   Around neutral position (within±100°) average (A): Refer to  "PINION ROTATING TORQUE "

   Maximum variation (B): Refer to  "PINION ROTATING TORQUE "

   Fig 4: Rack Assembly Turning Angle Versus Torque Graph

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4. Turn pinion fully to left.
5. Install dial gauge at 5 mm (0.20 in) (L) from the edge of gear housing assembly (1), and tooth point.
6. Measure vertical movement of rack assembly when pinion is turned clockwise with torque of 19.6 N.m (2.0 kg-m, 14 ft-lb).

   Readjust adjusting screw angle if the measured value is outside the standard.

   Vertical movement: 0.265 mm (0.0104 in) 

   Fig 5: Measuring Vertical Movement Of Rack Assembly Using Tool

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   • If reading is outside of the specification, readjust screw angle with adjusting screw.
     CAUTION:

     • 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.
     • Never turn adjusting screw more than twice.
     • Replace steering gear assembly when adjusting screw is removed or turned more than twice.

1. Tighten large side of boot with boot clamp (stainless wire).

   Wire length (L): 370 mm (14.57 in) 

   Fig 7: Tightening Large Side Of Boot Using Boot Clamp (Stainless Wire)

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2. Wrap clamp around boot groove for two turns. Insert a flat-bladed screwdriver in loops on both ends of wire. Twist 4 to 4.5 turns while pulling them with force of approximately 98 N (10 kg, 22 lb).
3. Twist boot clamp as shown below. Pay attention to relationship between winding and twisting directions.
   Fig 8: Twisting Boot Clamp

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4. Twisted area (A) of clamp is in the opposite side of adjusting screw (1) as shown in the figure (to prevent contact with other parts).
   Fig 9: Identifying Clamp Twisted Area

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5. Bent cut end of the wire as shown in the figure below after twisting the wire 4 to 4.5 turns so that cut end does not contact with boot.
   CAUTION: Keep gap from cylinder tube 5 mm (0.20 in) or more.

   Wire angle (A): 45° 

   Fig 10: Identifying Wire Bent Cut End Angle

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Inner socket length (L): Refer to  "INNER SOCKET LENGTH ".

Fig 11: Identifying Inner Socket Length

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