Assembly Of Gear Housing

1. PACK MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE

2. INSTALL RACK INTO RACK HOUSING

(a) From the pinion side, install the rack into the rack housing.

(b) Set the rack notched side so that the pinion can be positioned inside.

(c) Line up the cutout portion of the rack with the pinion.

3. INSTALL PINION INTO HOUSING

Insure that the pinion end is securely in the lower bearing.

4. INSTALL PINION BEARING ADJUSTING SCREW

(a) Coat sealant onto the screw threads.

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

(b) Using SST, install the pinion bearing adjusting screw.

SST 09612-24014 (09616-10020)

5. ADJUST PINION PRELOAD

(a) Line up the cutout portion of the rack with the pinion.

(b) Using SST, tighten the pinion bearing adjusting ^ screw to the point where the turning torque is 3.7 kg-cm (3.2 in.-lb, 0.4 Nm).

SST 09612-24014 (09616-10010, 09616-10020)

(c) Using SST, loosen the pinion bearing adjusting screw to the point where the turning torque is 2.3 -3.3 kg-cm (2.0 - 2.9 in.-lb, 0.2 - 0.3 N m).

SST 09612-24014 (09616-10010, 09616-10020)

6. INSTALL PINION BEARING ADJUSTING SCREW LOCK NUT

(a) Apply sealant to 2 or 3 threads of the lock nut.

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

(b) Using SST, install the lock nut.

SST 09612-10093 (09617-10010) and 09612-24014 (09616-10020)

HINT: Use a torque wrench with a fulcrum length of 425 mm (16.73 in.).

(c) Recheck the pinion preload.

If incorrect, readjust.

7. INSTALL RACK GUIDE AND SPRING

8. INSTALL RACK GUIDE SPRING CAP

(a) Apply sealant to 2 or 3 threads of the cap.

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

(b) Mesh the rack with the pinion.

(c) Using SST, install the rack guide spring cap. SST 09612-24014 (09612-10022)

9. ADJUST TOTAL PRELOAD

(a) Using SST, tighten the rack guide spring cap. SST 09612-24014 (09612-10022)

(b) Using SST, return the rack spring cap 25°. SST 09612-24014 (09612-10022)

Loctite Thread Locking Guide Chart

(c) Measure the total preload with SST.

SST 09612-24014 (09616-10010)

Preload (turning): 6-13 kg-cm

• If preload is insufficient:

Retorque the rack guide spring cap, and return it 12° or slightly less.

• If there is excess preload:

Slightly return the rack guide spring cap.

10. INSTALL RACK GUIDE SPRING CAP LOCK NUT

(a) Apply sealant to 2 or 3 threads of the lock nut.

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

(b) Using SST, install the lock nut.

SST 09612-10093 (09617-10010) and 09612-24014 (09612-10022)

HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.).

(c) Recheck the total preload. If incorrect, readjust.

Preload (turning): 6-13 kg-cm

11. INSTALL RACK ENDS

(a) Install new claw washers.

HINT: Align the claw of the claw washer with the rack groove.

(b) Using SST, install the rack ends.

SST 09612-10093 (09628-10020) and 09612-24014 (09617-24011)

HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.).

(c) Using a brass bar and hammer, stake the claw washers.

12. INSTALL RACK BOOTS

(a) Install the rack boots.

HINT: Be careful not to damage or twist the boot. The left and right boots are different. Be careful not to inter- ~ change them.

(b) Install the clamps and clips.

HINT: Face the open ends of the clip outward as shown, to avoid damage to the boot.

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13. INSTALL TIE ROD ENDS

(a) Screw the lock nuts and tie rod ends onto the rack ends until the matchmarks are aligned.

(b) After adjusting toe-in, torque the lock nuts. Torque: 570 kg-cm (41 ft-lb, 56 Nm)

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