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Power Steering Gear Box: Reassembly

  1. Lubricate bearing surface of side cover and install needle roller bearings. Apply grease to bottom of side cover. Install "O" ring to side cover.
  2. Insert adjusting bolt and plate into "T" slot on top of cross shaft, and set play with adjusting shims. Cross shaft play is 0-.002" (0-0.5 mm).
  3. When installing adjusting shims, place chamfered edge of adjusting plate to contact surface of cross shaft. See  Fig 1 .  Align cross shaft with side cover and tighten with adjusting bolt.
    Fig 1: Adjusting The Cross Shaft "T" Slot
    G09362075Courtesy of CHRYSLER GROUP, LLC

    Place chamfered edge of adjusting plate to contact surface of cross shaft.

  4. Tighten lock nut temporarily. Apply grease to oil seal lip and press in oil seal and ball bearing to top cover. Apply grease to "U" packing and lip of oil seal and press in to gear box.
  5. Install "O" ring and seal ring to input worm shaft. Install thrust plates and needle bearings in input worm units. Install top cover side thrust plate with smaller outside diameter first.
  6. Install "O" ring and seal ring (compressed into heart shape) into valve housing. Install input worm shaft to the valve housing. Install thrust plate, needle roller bearing and thrust plate in that order to top cover.
    NOTE: Install thinner thrust plate to top cover side.
  7. Tighten top cover to the valve housing using pin tool (MB990853). Check worm shaft for uniform rotation. Tighten valve housing lock nut with spanner wrench (MB990852). Take care not to allow top cover to rotate.
    NOTE: Tighten final valve housing lock nut when measurement of total starting torque is reached.
  8. Measure starting torque using preload socket (CT-1108). Preload should be 2.2-5.6 INCH lbs. (.3-.6 N.m). Adjust, if necessary, by loosening valve housing nut and retightening. Install "O" ring and seal ring to rack piston.
  9. Insert rack-piston into input worm shaft until piston touches worm shaft end. Rotate worm shaft and align ball running surface with ball insertion hole. Insert 19 balls into hole by pushing lightly with a brass rod. See  Fig 2 . 
  10. Measure distance from rack-piston to balls. If distance is more than 0.5" (13 mm), a ball is in wrong groove. Remove and reinstall balls correctly.
    Fig 2: Installing Circulator Balls To Rack Piston
    G09362076Courtesy of CHRYSLER GROUP, LLC

    Install balls using a brass rod to push in.

  11. Insert 7 more balls with grease to prevent them from falling. Insert circulator and holder to rack piston attaching place and tighten. Hold gear box in a vise.
  12. Apply a thin coating of automatic transmission fluid to teeth and shaft of rack piston. Apply grease to oil seal lip. Install ball screw unit. Tighten valve housing. Do not allow cover to rotate.
  13. Wrap serration of cross shaft with vinyl tape to avoid damage when installing. Install cross shaft and side cover to gear box. Tighten side cover.
  14. Measure starting torque of input worm shaft using preload socket (CT-1108). Adjust to 4.3-7.8 INCH lbs. (.5-.9 N.m).
  15. Make sure ball screw unit operates smoothly. Tighten valve housing lock nut with spanner (MB990852). Check preload. Connect cross shaft with Pitman arm.
    NOTE: When connecting cross shaft with Pitman arm, align slit of cross shaft tip to marking on Pitman arm. Clearance between bolt hole center in gear box and Pitman arm should be 0.77" (19.5 mm).
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