MR2 L4-132 2164cc 2.2L DOHC (5S-FE) (1993)
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9.
Remove rack from pinion side without turning it.
Inspection & Assembly
1.
Check rack teeth and back for wear or damage.
2.
Ensure rack runout does not exceed .012 inch (.3mm).
3.
Inspect pinion bearings, Fig. 5.
4.
If necessary, replace pinion bearing as follows:
a. Remove upper bearing using suitable tool.
b. Install new upper bearing using suitable tool.
5.
If necessary, replace lower pinion bearing as follows:
a. Heat rack housing to over 176°F (80°C).
b. Using plastic hammer, tap housing to free bearing.
c. Reheat rack housing to over 176°F (80°C).
d. Using suitable tool, install new lower bearing taking care to note correct bearing direction.
6.
If necessary, replace rack bushing as follows:
a. Using suitable tool, remove rack bushing.
b. Ensure tube hole is not blocked with grease.
c. Install new rack bushing using suitable tool. Press new bushing in until edge surface of rack tube is even with surface of service tool.
7.
If necessary, replace pinion oil seal as follows:
a. Using suitable tools, remove pinion oil seal.
b. Using service tools used above, drive new pinion seal in so it protrudes .020 inch (.5mm). During remaining assembly, coat all friction
surfaces with molybdenum disulfide lithium based grease.
8.
Install rack into housing from pinion side. Position notched portion of rack so that pinion can be positioned inside.
9.
Line up cutout portion of rack with pinion and install pinion making sure that pinion end is securely positioned in lower bearing.
10.
Apply liquid sealer to threads of pinion bearing adjusting screw. Install screw using tool 09612-24012 or equivalent.
11.
Line up cutout portion or rack with pinion.
12.
Using service tool used previously, tighten pinion bearing adjusting screw so pinion turning torque is 3.2 inch lbs.
13.
Loosen pinion bearing adjusting screw until pinion turning torque is 1.3-2.2 inch lbs.
14.
Apply liquid sealer to pinion bearing adjusting screw locknut and install locknut. Using suitable tools, tighten locknut to specifications. Recheck
pinion preload and adjust, if necessary.
15.
Install rack guide with spacer and spring.
16.
Apply liquid sealer to guide spring cap threads
17.
Mesh rack with pinion and install rack guide spring cap using suitable tool or equivalent.
18.
Count total number of pinion rotations possible and return pinion half that amount to position pinion in neutral position.
19.
Adjust total preload as follows:
a. Torque rack guide spring cap to 18 ft. lbs.
b. Return rack guide spring cap 25°.
c. Measure total preload within on rotation from neutral position in both directions. Preload should be 6.9-11.3 inch lbs.
d. If preload is insufficient, retorque guide spring cap and return slightly less than 12°.
e. If preload is excessive, return rack guide spring cap slightly.
20.
Apply liquid sealer on locknut thread and rear housing surface. Install locknut and torque to specifications
21.
Recheck total preload. Adjust, if necessary.
22.
Install dust cover.
23.
Install claw washers and rack ends. Tighten rack end to specifications, using suitable tool, then stake claw washer.
24.
Install rack boots taking care not to damage or twist boots. Note difference between right and left boots.
25.
Install clamps and clips with open ends facing outward to avoid damage to boots.
26.
Install tie rod ends so marks are aligned. Adjust toe-in and torque locknuts to specifications.
