Steering Rack Plunger Removal and Installation: Installation

Reference: STEERING RACK PLUNGER INSPECTION 

1. Install new O-ring (2) to steering rack plunger (1).
2. Apply grease supplied with new O-ring to steering rack plunger, O-ring and sliding face of steering gear case that contacts steering rack plunger.
3. Install steering rack plunger, spring washer (3) and steering rack plunger spring (4).
4. Apply sealant to steering rack damper screw (5) and steering rack damper screw lock nut (6) and tighten steering rack damper screw as follows.
   1. Tighten to 25 N.m (2.5 kgf-m, 18.5 lbf-ft).
   2. Loosen to 0 N.m (0 kgf-m, 0 lbf-ft).
   3. Retighten to 5.0 N.m (0.5 kgf-m, 3.7 lbf-ft).
   4. Tighten to specified torque and then loosen by 13 ± 1°

      "A": Sealant 99000-31250 (SUZUKI Bond No. 1207F) 

      Tightening torque 

      Rack damper screw* (a): 25 N.m (2.5 kgf-m, 18.5 lbf-ft) → 0 N.m (0 kgf-m, 0 lbf-ft) → 5.0 N.m (0.51 kgf-m, 4.0 lbf-ft) → loosen by 13 ± 1° 

      Fig 1: Identifying Steering Rack Plunger Components

      Courtesy of SUZUKI OF AMERICA CORP.
      Fig 2: Identifying Rack Damper Screw

      Courtesy of SUZUKI OF AMERICA CORP.
5. Tighten steering rack damper screw lock nut to specified torque.

   Tightening torque 

   Steering rack damper screw lock nut (a): 59 N.m (6.0 kg-m, 43.5 lbf-ft) 

6. Install steering gear case, see STEERING GEAR CASE ASSEMBLY REMOVAL AND INSTALLATION .