Disassembly and Reassembly

RACK AND PINION

- Tools Required
- KM-J-22610 Installer

Disassembly Procedure
1. Remove the rack and pinion steering assembly from the vehicle.
2. Remove the valve and pinion assembly from the rack and pinion steering assembly.
3. Remove the rack bearing assembly from the rack and pinion steering assembly.
4. Mark the threads on the inner tie rod to aid in repositioning the adjusting nut.





5. Loosen the adjusting nut and remove the outer tie rod nut and the adjusting nut.





6. Remove the dust boot retaining clamps.





7. Remove the dust boot.





8. Push back the plastic retainer that protects the connection between the inner tie rod and the power steering gear rack.





9. Counterhold the pinion-side inner tie rod and remove the cylinder-side inner tie rod.





10. Place a rag over the rack, counterhold the rack assembly on the teeth with a wrench, and remove the pinion-side inner tie rod.

IMPORTANT: The retaining ring can be released by inserting a small screwdriver through the hole in the side of the housing.





11. Remove the bulkhead inner cylinder retaining ring the bulkhead inner cylinder and the rack.

Assembly Procedure

NOTICE: Coat all the seals with power steering fluid to ensure proper sealing.





1. Install the rack, the bulkhead inner cylinder, and the bulkhead inner cylinder retaining ring.

NOTICE: To prevent the inner tie rods from loosening, use Loctite 242, or equivalent, on both inner tie rod connections to secure them to the rack shaft.

IMPORTANT: The right and the left inner tie rods are unequal in length. Be sure to install the correct inner tie rod on the proper side of the power steering gear.





2. Firmly seat the inner tie rods against the rack and tighten both ends simultaneously.
Tighten
Tighten the inner tie rods to 100 Nm (74 ft. lbs.).





3. Push the plastic retainer back onto the connection between the inner tie rod and the power steering gear rack.





4. Install the dust boot.





5. Install the cylinder end dust boot retaining clamps with the installer KM-J-22610.





6. Install the tie rod end boot retaining clamps.
7. Reposition the adjusting nut to the marks on the inner tie rod and install the outer tie rod by twisting it onto the inner tie rod.
8. Perform a front toe adjustment.





9. Tighten the adjusting nut.
Tighten
Tighten the outer tie rod adjusting nut to 64 Nm (47 ft. lbs.).
10. Install the rack bearing assembly into the rack and pinion steering assembly.
11. Install the valve and pinion assembly into the rack and pinion steering assembly.
12. Install the rack and pinion steering assembly into the vehicle.