Tie-Rod/Rack Boot Removal and Installation: Installation

Install tie-rod (1) and tie-rod lock washer to rack (2).
Hold rack with soft jawed vise and tighten tie-rod to specified torque.
Tightening torque

Tie-rod (a): 75 N.m (7.5 kg-m, 54.5 lbf-ft)

Fig 1: Installing Tie-Rod And Tie-Rod Lock Washer To Rack
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Bend lock washer at 2 places (1) as shown in figure.

Fig 2: Bending Lock Washer
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Apply grease "A" to boot inside as shown in figure. Position boot properly in grooves of gear case (or rack side mount) and tie-rod.
After this, check to ensure that boot is free from twist and dent.

"A": Grease 99000-25050 (SUZUKI Super Grease E)

Fig 3: Applying Grease "A" To Boot Inside
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Clamp boot with clip and wire. Wire should be new and should go around the boot twice. Pull its both ends together by screwdriver or such and make sure that the wire won't be crossed. Then twist the ends 4 - 5 times, the twisted ends should be bent in the circumferential direction.
NOTE: After clamping, make sure that the boot installation part is fixed.
If the boot turns easily by hand, tighten with higher torque to fix it firmly.

Fig 4: Clamping Boot With Clip And Wire
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Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock nut to marking (1) made in removal.
NOTE: When tie-rod was replaced, measure length "a" on removed tie-rod and use it on new replacement tie-rod so as to position lock nut properly.

Fig 5: Tie-Rod End Lock Nut Measurement
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Tighten tie-rod end lock nut to specified torque referring to TIE-ROD END REMOVAL AND INSTALLATION (Hydraulic Type).
Install member bracket (1), and then install earth cable (2) as shown in figure.
Angle "a"

: Within 20°

Tightening torque

Earth cable bolt (a): 4.0 N.m (0.4 kg-m, 2.8 lbf-ft)

Fig 6: Identifying Earth Cable Bolt Tightening Angle
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