Rack Assembly: Reassembly
- Lubricate all "O" rings, seals and sleeves before installation. Also lubricate all moving parts before installation. Install seal and "O" ring to end housing.
- Install new center feed porting adapter to porting ring. Position ring to allow conical seating on adapter to engage with seating on cylinder and tighten.
- Install rack seal over rack teeth up against piston. Install anti-extrusion ring to recess in back of rack seal. Lubricate inside of rack housing and grease rack. Insert rack into rack housing with firm steady pressure until seal seats against abutment face.
- Ensure piston ring collapses and enters rack housing without damage. Install new seal, washer and snap ring to pinion housing. Install new pinion valve seal to pinion shaft (located against pinion bearing).
- Lubricate pinion shaft, piston seals, and bearing. Carefully install pinion shaft to pinion housing. Tap gear end of shaft lightly to ensure it is seated.
- Grease pinion teeth and small pinion journal. Install pinion, housing and new gasket to rack housing. Ensure rack teeth and pinion teeth mate correctly.
- Ensure pinion housing ports are correctly aligned so cylinder-to-valve pipes can be installed. Install seals to end housing.
- Install end housing-to-rack housing and screw locking ring into end housing just enough to hold mounting feet in parallel alignment.
- With end housing and mounting feet in alignment, tighten locking ring. Install rack plunger, spring, adjusting plug and lock nut. Tighten adjusting plug, while moving rack through full stroke, until rack is hard to move.
- Back off adjusting nut just enough to obtain a smooth rack movement (approximately 1/8 turn). Tighten lock nut while holding adjusting plug from turning.
- Install air transfer pipe and cylinder-to-valve pipes. Place bellows onto tie rods with small opening towards outer ball joint. Install tie rod inner ball joint to rack. Ensure lock washer tab is aligned with slot in rack end.
- Pull rack out until rack teeth can be held in soft-jawed vise. Tighten tie rod inner ball joint lock nut. Repeat procedure for other tie rod. Bend lock washer tab into rack slots with punch.
- Place 1 to 2 oz. of grease into each bellows. Attach bellows to rack housing and tie rod with wire clips. Remove plug in rack plunger adjusting plug and install grease nipple.
- Using a hand grease gun, fill with approximately 5 strokes of the grease gun. Remove grease nipple and install plug.