- Lubricate bearing surface of side cover and install 33 roller
bearings. Apply grease to bottom of side cover. Install "O" ring to
side cover.
- Insert adjusting bolt and plate into "T" slot on top of cross
shaft. Using adjusting plates, set cross shaft play to 0-.002" (0-0.5
mm). See CROSS SHAFT
ADJUSTING PLATE THICKNESS
table.
CROSS SHAFT ADJUSTING PLATE THICKNESS
| Plate No. |
In. (mm) |
| 1 |
.077 (1.95) |
| 2 |
.079 (2.00) |
| 3 |
.081 (2.05) |
| 4 |
.083 (2.10) |
| 5 |
.085 (2.15) |
- When installing adjusting plates, 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.
DO NOT
allow bearing to
fall off or damage seal ring. Tighten lock nut temporarily.
- Apply grease to oil seal lip. Press oil seal and ball bearing
into top cover. Apply grease to "U" packing and lip of oil seal and
press into gear box.
- Install "O" ring and seal ring to input worm shaft. Install
thrust plate, needle bearing, and thrust plate in that order onto
input worm shaft. Install "O" ring and seal ring (compressed into hear
shape) into valve housing groove.
- Install input worm shaft to 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.
- Temporarily tighten top cover to valve housing using Spanner
Wrench (MB990853). Ensure thrust plate and needle bearing are aligned.
Attach spring tension gauge to spanner wrench and tighten cover 14-19
lbs. (6.4-8.6 kg). Then loosen cover to 0 lbs. (0 kg). See Fig 2
. Check input worm
shaft for uniform rotation.
- Using Preload Socket (CT-1108) and INCH Lb. torque wrench,
measure and record input worm shaft starting torque. Gradually tighten
top cover until input worm shaft starting torque is 1.8-2.7 INCH Lbs.
(.2-.3 N.m) greater than recorded value. Using Spanner Wrench
(MB990852) and torque wrench, tighten valve housing nut without
rotating top cover.
- Again measure input worm shaft starting torque while turning
input worm shaft. If starting torque is not 2.2-5.6 INCH Lbs. (.3-.6
N.m), loosen valve housing nut and repeat steps 7) and 8). Install "O"
ring and seal ring to rack piston without forcing. 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 (except 4WD models). After installation, ensure ball-to-rack
piston clearance is .5" (13 mm). See Fig 3
. If clearance is
excessive, a ball has entered wrong groove. Remove rack piston and
reinstall balls.
NOTE:
DO NOT
rotate
input worm shaft and rack piston. Balls may
enter wrong grooves.
- Insert 7 more balls with grease to prevent them from falling.
Insert circulator and holder to rack piston and tighten. Mount gear
box in vise and install valve housing and rack piston. Tighten valve
housing. Rotate input worm shaft to move rack piston to center
(neutral) position.
NOTE:
DO NOT
force rack
piston into housing. Seal ring may be
damaged by edge of gear housing.
- Apply a thin coating of automatic transmission fluid to teeth
and shaft of rack piston. Apply grease to oil seal lip. Wrap serration
of cross shaft with vinyl tape to avoid damage when installing.
Install cross shaft and side cover to gear box.
DO NOT
rotate side
cover for installation to prevent damage to "O" ring. Tighten side
cover.
- Using Preload Socket (CT-1108), measure starting torque of input
worm shaft. Adjust to 4.3-7.8 INCH Lbs. (.5-.9 N.m) by turning cross
shaft adjusting bolt. Tighten lock nut. Ensure valve housing and rack
piston unit operates smoothly.
- Connect cross shaft to pitman arm. Ensure slit on cross shaft
tip aligns with groove on pitman arm.