Gear Box: Assembly

NOTE: Always coat new "O" rings with grease during installation.

Pack new upper pinion bearing with grease. If installing new bearing, use Driver (07949-6110000 ). Apply grease to pinion holder and gear housing needle bearings. Install pinion holder in gear housing and retain with snap ring.
Set gear housing aside. Install new "O" ring on rack with narrow edge facing away from rack. Apply steering fluid to Guide (07974-SA50100 ). Slide guide, large end first, onto rack.
Slide new piston ring over guide and into piston groove, over "O" ring. Coat piston and Sizer (07974-SA50200 ) with steering fluid. Slide sizer onto rack and over piston ring. Slide and rotate sizer over piston ring to break-in new ring.
Grease and install "O" rings on cylinder cap. Slide cylinder cap onto seal retainer and install snap ring and "O" ring. Grease sliding surface of new White cylinder end seal. Install seal with grooved end facing out.
CAUTION: Both cylinder end seals are same size but are not interchangeable; White seal goes in end of seal retainer, Black seal in end of cylinder housing.
Install new "O" ring and retainer washer into gear housing. Install seal retainer into gear housing. Stand housing on end with flange end up. Coat Cylinder End Seal Slider (07974-SA50300 ) with grease.
Ensure slider surface isn't damaged. Set seal slider over seal, in end of retainer. Coat rack and fill teeth with grease. Insert rack into seal retainer, making sure rack teeth do not face slot in seal slider.
Pull slider out of seal retainer. Spread ends and remove from rack. Coat inside surface of cylinder barrel with steering fluid. Slide cylinder barrel over rack until it seats against seal retainer.
Install cylinder spring over rack. Coat rack bushing with steering fluid and install on spring. Grease End Seal Guide (07074-SA50400 ) and push onto end of rack.
Coat seal contact surface of cylinder housing with steering fluid. Install Black cylinder end seal (groove facing out). Carefully slide cylinder housing over rack until it contacts gear housing. Remove seal guide.
Lay gear box down and push right end of rack into cylinder housing. Install cylinder housing retaining bolts. Set assembly aside. Press in lower pinion bearing with cover facing away from shaft. Install pinion snapring.
Grease lower bearing, install pinion into pinion holder and install snap ring. Coat lip of pinion dust seal with grease and install in retainer. Install retainer "O" ring.
Grease Dust Seal Guide (07974-SA50600 ) and install over pinion shaft. Install retainer and tighten bolts. Install control unit on housing. Grease rack and install rack guide, spring, "O" ring and rack guide screw.
Tighten guide screw until it compresses spring and seats against guide, then loosen it. Tighten to 26 INCH lbs. (3 N.m) then back off 35° (1/10 turn). Hold guide screw and tighten lock nut to 18
1. lbs. (25 N.m).
Reverse removal procedure to complete installation. Tighten all fasteners to specification and adjust steering shaft. See STEERING SHAFT . Add fluid, bleed system and check for leaks.