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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.
    NOTE: When lubricating components with grease, DO NOT  cover air passages in housing bushing.
  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. Recenter rack and reinstall pinion shaft. Select and install snap ring. To minimize pinion shaft axial play on Colt Vista and Precis, see the SNAP RING THICKNESS COLOR CODING (COLT VISTA & PRECIS)  table.
    SNAP RING THICKNESS COLOR CODING (COLT VISTA & PRECIS)

    Color Code In. (mm)
    Blue .063 (1.59)
    White .066 (1.66)
    Yellow .069 (1.74)
  5. On all models, 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. On Colt, Colt 200, Eclipse, Mirage and Summit, tighten adjusting screw (plug) to 11 ft. lbs. (15 N.m). On Colt Vista, tighten adjusting screw to 60-84 INCH lbs. (7-9 N.m). On Precis, tighten adjusting plug to 96 INCH lbs. (11 N.m).
  7. Back off adjusting screw (plug) 30-60 degrees. Apply sealer to adjusting screw (plug) lock nut threads. Tighten adjusting plug lock nut to 36-51 ft. lbs. (50-70 N.m).
  8. Install tie rod assemblies with new tab washers. Stake tie rod-to-rack end nuts. Install bellows and bellows clamps.
  9. Using a socket and torque wrench, measure rack starting force. See RACK STARTING FORCE SPECIFICATIONS  table. If rack starting force is not within specifications, replace plunger spring and rubber cushion. Recheck rack starting force.
RACK STARTING FORCE SPECIFICATIONS

Application INCH Lbs. (N.m)
Colt, Colt 200, Mirage & Summit 3-12 (.3-1.4)
Colt Vista 6-11 (.7-1.3)
Eclipse
Zero-90 Degrees 5-11 (.6-1.3)
90-650 Degrees 2-9 (.2-1.0)
Precis 4-10 (.4-1.1)
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