Steering Gear: Reassembly

Clean all components in solvent. Always use new seals. Using an appropriate sleeve and press, install pinion shaft bearing onto pinion shaft.
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.
Install rack into housing from pinion shaft side of housing. Install pinion shaft into housing while meshing pinion shaft with rack teeth.
Ensure rack is properly centered. Measure travel of rack at each end of housing. If travel is not equal, remove pinion shaft. Re-center rack, and reinstall pinion shaft. Select and install snap ring.
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.
Tighten adjusting screw (plug) to 11 ft. lbs. (15 N.m).
Rack 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).
Install tie rod assemblies with new tab washers. Stake tie rod-to-rack end nuts. Install bellows and bellows clamps.
Using a socket and torque wrench, measure rack starting force. See RACK STARTING FORCE SPECIFICATIONS table. If rack starting force is not within specification, replace plunger spring and rubber cushion. Recheck rack starting force.

RACK STARTING FORCE SPECIFICATIONS

Application	INCH Lbs. (N.m)
0-90 Degrees	5-11 (0.6-1.3)
90-650 Degrees	2-9 (0.2-1.0)