1. Assemble in the order indicated in the table.
1
|
Gear housing
|
2
|
Mounting rubber
|
3
|
Oil seal
|
4
|
Inner guide
|
5
|
O-ring
|
6
|
Seal ring
|
7
|
Steering rack
|
8
|
U-gasket
|
9
|
O-ring
|
10
|
Holder
(See Holder Assembly Note)
|
11
|
Oil seal
(See Oil Seal Assembly Note)
|
12
|
Valve housing
|
13
|
Upper bearing
|
14
|
Pinion shaft
|
15
|
Control valve
|
16
|
Seal ring
(See Seal Ring Assembly Note)
|
17
|
Snap ring
|
18
|
O-ring
|
19
|
Bolt
|
20
|
Support yoke
|
21
|
Yoke spring
|
22
|
Spring washer
|
23
|
Adjusting cover
|
24
|
Locknut (adjusting cover)
|
25
|
Washer
|
26
|
Tie rod
|
27
|
Boot
|
28
|
Boot band
|
29
|
Boot clamp
|
30
|
Locknut
|
31
|
Tie-rod end
|
32
|
Oil pipe
|
1. Apply soapy water to the rubber part of the mounting rubber.
2. Install the mounting rubber so that two notches of the mounting rubber are aligned to the steering rack.
3. Press the mounting rubber using the SSTs and a press until the end of the mounting rubber comes out completely from the gear housing.
4. Reverse the gear housing, then press the mounting rubber until the end of the mounting rubber comes out completely from the other side. At this time, align the end of the mounting rubber and the steel pipe.
1. Install a new O-ring and seal ring to the piston part of the rack.
2. After installing the seal ring, seat it properly at the piston circumference.
3. Apply grease to a new oil seal and inner guide.
4. Install the oil seal to the SSTs.
5. Use the SST to move the oil seal to the edge of the steering rack piston.
6. Install the inner guide.
7. Put the steering rack into the gear box.
8. Press the oil seal and inner guide using the SSTs and a press until the force required suddenly increases.
1. Apply grease to a new U-gasket and O-ring.
2. Install the U-gasket and O-ring to the holder.
3. Set the SST to the steering rack, and install the holder.
4. Stake the holder to the gear housing using a punch.
1. Apply grease to a new oil seal.
2. Press a new oil seal in using the SSTs and a press.
1. Apply grease to a new bearing.
2. Press the bearing in using the SSTs.
1. Install a new seal ring to the valve part of the pinion shaft using the SST.
2. Using the SST, seat the seal ring properly.
3. Install the snap ring.
1. Set the rack to the center position.
2. Tighten the adjusting cover with 19.6 N·m {2 kgf·m, 14.5 ft·lbf} three times using the SST, and then turn back the adjusting cover to 44°.
3. Apply sealant to the threads of the locknut.
4. Attach the locknut.
5. Measure the rotational torque using the SST and a pull scale.
Rotational torque
6. If not within the specification, repeat Steps 2-5.
7. Install the locknut using the SST (49 B032 320).
Tightening torque
1. Connect the SST to the power cylinder section of the gear housing.
2. Apply 53.3 kPa {400 mmHg, 15.7 inHg} vacuum with a vacuum pump and verify that it is held for at least 30 s.