Steering Gears & Linkage: Overhaul: Reassembly
- Reassemble by reversing disassembly procedure and note the following: Ball joints linking tie rods to rack must be a fairly tight sliding fit without play. Adjustment of this play is made by varying thickness of shims fitted beneath ball joint cap seat. Install and lock new tab washers.
- Place thickest of pinion thrust washers in position in rack housing with its chamfered edge toward rack. Replace smaller thrust washer on plain end of pinion shaft with chamfered edge toward pinion teeth. Ensure center tooth on rack is in line with mark on splined end of pinion when inserting pinion.
- Excessive end play of pinion is corrected by fitting shims of proper thickness with lower bearing. To measure this, place a dial gauge at end of pinion shaft. End play should be 0.002 - 0.005" (.05-.13 mm).
- Replace ball joint lock nuts and joint assemblies in approximately original position (use measurement recorded during disassembly).
- To replace and adjust rack damper, position plunger in cap and replace cap. Screw down cap until it is just possible to rotate pinion shaft by drawing rack through housing. With feeler gauge, measure clearance between hexagon of damper cap and its seating in rack housing. To this measurement, add 0.002 - 0.005" (.05-.13 mm) to determine thickness of shims necessary to place beneath cap.
- Remove damper cap and plunger. Insert spring beneath plunger; reassemble damper with shims. Install new pinion oil seal and fill housing with approximately 10 fl. oz. (.28 liter) of oil.
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