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Steering Gear: Reassembly

  1. Clean all components in solvent. Always use new seals. Using an appropriate sleeve and press, install pinion shaft bearing onto pinion shaft.
  2. Install bearing snap ring to pinion shaft. Grease rack, pinion shaft, bushing, needle bearing and other sliding surfaces. DO NOT  cover air passages in housing bushing with grease.
  3. Install rack into housing from pinion shaft side of housing. Install pinion shaft into housing while meshing pinion shaft with rack teeth.
  4. Ensure rack is properly centered. Measure travel of rack at each end of housing. If travel is not equal, remove pinion shaft. Center rack, and install pinion shaft. Select and install snap ring.
  5. Install pinion shaft top cover and locking nut. Tighten nut to specification. See TORQUE SPECIFICATIONS  . Grease oil seal lip and oil seal-to-housing mating surface. Install oil seal into housing. Grease rack support. Install rack support, rubber cushion, plunger spring and adjusting plug into housing. Center rack.
  6. Tighten adjusting screw (plug) to 11 ft. lbs. (15 N.m). Back off adjusting screw (plug) 30-60 degrees. Apply sealant to adjusting screw (plug) lock nut threads. Tighten adjusting plug lock nut to 36-51 ft. lbs. (50-70 N.m).
  7. Install tie rod assemblies with new tab washers. Stake tie rod-to-rack end nuts. Install bellows and bellows clamps.
  8. Using a socket and torque wrench, measure rack starting force. Rack starting force should be 3-12 INCH lbs. ((0.3-1.4 N.m). If rack starting force is not within specification, replace plunger spring and rubber cushion. Recheck rack starting force.
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