Power Steering Gear: Reassembly

1. Coat a new oil seal lip with power steering fluid.
2. Install the oil seal to SST, and press them into the rack housing.

   SST 09950-60010 (09951-00250, 09951-00430, 09952-06010), 09950-70010 (09951-07360)

   NOTE:

   • Make sure that the oil seal is installed facing in the correct direction.
   • Take care that the oil seal does not get reversed as you install it.
   Fig 1: Installing Oil Seal To SST And Pressing Them Into Rack Housing

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3. INSTALL STEERING RACK 
4. Install SST to the rack.

   SST 09631-33010

   HINT:

   If necessary, scrape the burrs off the rack teeth end and burnish.

5. Coat SST with power steering fluid.
6. Install the steering rack into the rack housing
Fig 2: Installing Steering Rack Into Rack Housing
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7. Remove the SST.

   SST 09631-33010

1. Coat a new oil seal lip with power steering fluid.
2. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.
3. Install the oil seal by pushing it into the rack housing with out tilting.

Fig 3: Installing Oil Seal

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1. Install the spacer.
2. Coat a new O-ring with power steering fluid and install it to the cylinder end stopper.
3. Using a wooden block and hammer, drive in the cylinder end stopper until it is tightly installed.
   NOTE: Be careful not to damage the O-ring.
   Fig 4: Installing Cylinder End Stopper And Spacer

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4. Using SST, torque the cylinder end stopper.

   SST 09631-20090

   Torque: 59 N.m (600 kgf.cm, 44 ft.lbf) 

Fig 5: Torquing Cylinder End Stopper

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1. Install SST to the rack housing.

   SST 09631-12071

2. Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for about 30 seconds.
3. Check that there is no change in the vacuum.

If there is a change in the vacuum, check the installation of the oil seals.

Fig 6: Performing Air Tightness Test

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1. Coat the teflon rings with power steering fluid.
2. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.
3. Push the control valve assembly into the control valve housing.

Fig 7: Installing Control Valve Assembly

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1. Coat a new O-ring with power steering fluid, and install it to the bearing guide nut.
2. Using SST, install the bearing guide nut.

   SST 09631-20060

   Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

   NOTE: Be careful not to damage the oil seal lip.
   Fig 8: Installing Bearing Guide Nut Using SST

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3. Using a punch, stake the bearing guide nut.

Fig 9: Staking Bearing Guide Nut

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1. Coat a new O-ring with power steering fluid, and install it to the control valve housing.
2. Align the matchmarks on the valve housing and rack housing.
3. Install the 2 bolts.

   Torque: 18 N.m (180 kgf.cm, 13 ft.lbf) 

Fig 10: Installing Control Valve Housing With Control Valve Assembly

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1. Install the rack guide sub-assembly, rack guide spring and conical spring.
   NOTE: Make sure that the conical spring is installed facing in the correct direction.
2. Apply sealant to 2 or 3 threads of the rack guide spring cap.

   Sealant: 

   Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

3. Temporarily install the rack guide spring cap.

Fig 11: Installing Rack Guide Sub-Assembly, Rack Guide Spring And Conical Spring

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1. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends.
2. Using a hexagon wrench (24 mm), torque the rack guide spring cap.

   Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

3. Using a hexagon wrench (24 mm), return the rack guide spring cap 12°.
   Fig 12: Torquing Rack Guide Spring Cap

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4. Using SST, turn the control valve shaft right and left 1 or 2 times.

   SST 09616-00011

   Fig 13: Turning Control Valve Shaft Right And Left

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5. Using a hexagon wrench (24 mm), loosen the rack guide spring cap until the rack guide spring is not functioning.
6. Using SST, a torque wrench and hexagon wrench (24 mm), tighten the rack guide spring cap until the preload is within the specification.

   SST 09616-00011

   Preload (turning): 

   1.2 - 1.7 N.m (12.2 - 17.3 kgf.cm, 10.6 - 15.0 in.lbf) 

Fig 14: Tightening Rack Guide Spring Cap

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1. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut.

   Sealant: 

   Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

2. Temporarily install the rack guide spring cap lock nut.
3. Using a hexagon wrench (24 mm), hold the rack guide spring cap and using SST, torque the rack guide spring cap lock nut.

   SST 09922-10010

   Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

   Fig 15: Torquing Rack Guide Spring Cap Lock Nut

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   NOTE: Use SST 09922-10010 in the direction shown in the illustration.

   HINT:

   Use a torque wrench with a fulcrum length of 345 mm (13.58 in.).

4. Recheck the total preload.

   Preload (turning): 

   1.2-1.7 N.m (12.2 - 17.3 kgf.cm, 10.6 - 15.0 in.lbf) 

5. Remove the RH and LH rack ends.

1. Install a new claw washer, and temporarily install the rack end.

   HINT:

   Align the claws of the claw washer with the steering rack grooves.

   Fig 16: Identifying Rack Grooves

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2. Using a spanner, hold the steering rack steadily and using SST, torque the rack end.

   SST 09922-10010

   Torque: 76 N.m (780 kgf.cm, 56 ft.lbf) 

   NOTE: Use SST 09922-10010 in the direction shown in the illustration.

   HINT:

   Use a torque wrench with a fulcrum length of 380 mm (14.96 in.)

   Fig 17: Using Spanner Hold Steering Rack Steadily And Using SST,

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3. Using a brass bar and a hammer, stake the washer.
   NOTE: Avoid any impact on the steering rack.
4. Employ the same manner described above to the other side.

Fig 18: Staking Washer

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1. Ensure that the steering rack hole is not clogged with grease.

   HINT:

   If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.

2. Install the boot, clip and a new clamp.
   NOTE: Be careful not to damage or twist the boot.
   Fig 19: Identifying Steering Rack Hole

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3. Tighten the clamp as shown in the illustration.
   Fig 20: Tightening Clamp

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4. Employ the same manner described above to the other side.

1. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.
Fig 21: Installing RH And LH Tie Rod Ends And Lock Nuts On Matchmark
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2. After adjusting toe-in, torque the nut. (See ALIGNMENT SPECIFICATIONS & PROCEDURES )

   Torque: 56 N.m (570 kgf.cm, 41 ft.lbf) 

3. Employ the same manner described above to the other side.

Using SST, install the 2 turn pressure tubes.

SST 09023-38200

Torque: 22 N.m (220kgf.cm, 16 ft.lbf) 

HINT:

• Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
• This torque value is effective in case that SST is parallel to a torque wrench.

Fig 22: Torquing 2 Turn Pressure Tubes

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