Steering Gear: Reassembly
- Apply grease to rack teeth, sliding portion of rack shaft, sleeve insertion hole, dust seal and dust cover hole. Press dust seal into steering gear. Maximum distance between end of rack housing and top of dust seal is .08" (2.0 mm).NOTE: Move rack shaft back and forth full stroke to squeeze grease which accumulates on both ends. Remove grease to prevent clogging of air passage hole.
- Apply grease to sliding surface of sleeve and spring seat. Insert sleeve into pinion housing. Insert spring into adjusting screw. Pack grease inside screw. Install screw.
- Rotate pinion shaft until rack shaft extends 1.57" (40 mm) beyond end of rack housing. Tighten backlash adjusting screw until it bottoms. Screw left and right side tie rods onto rack shaft. Left tie rod is grooved for identification and should be installed on pinion end of rack shaft.
- Bend each lock washer in 2 places. Tighten backlash adjusting screw to 43 INCH lbs. (5 N.m), and then loosen. Repeat this procedure twice. Retighten adjusting screw to 43 INCH lbs. (5 N.m), then back off 30 degrees. Tighten adjusting screw lock nut. Install tie rod boots.
- Place rack housing on Stand (926200000 ). Apply grease to teeth of rack shaft. Install cover from Cover and Remover Set (926390001 ) onto toothed section of rack shaft. Check air passage hole for excessive grease, and unclog if necessary.
- Apply Dexron-II ATF to cover and rack shaft piston ring. Insert rack shaft into rack housing from cylinder end of housing. Remove cover after rack shaft has passed completely through oil seal. Fit Guide (927660000 ) over end of rack shaft, dip rack bushing assembly in Dexron-II ATF and install rack bushing assembly.
- Install rack stopper into rack housing and wrap circlip into position using Wrench (926340001 ). Fit mount bushing onto rack housing. Rotate wrench an additional 90-180 degrees after end of circlip has been wrapped into housing.
- Place rack housing on Stand (926200000 ). Oil Seal Installer (926240000 ) consists of 3 pieces: "A", "B" and "C". See Fig 1 . Using installers "B" and "C", attach oil seal to installer "A". Insert installer "A" with oil seal into rack housing from gear side.
- Remove oil seal near rack shaft piston, and then remove Installer (926240000 ). Apply a coat of grease to rack teeth, sliding portion of sleeve and pistons sealing side. Install rack shaft into rack housing from cylinder end. Attach Guide (926250000 ) to cylinder end of rack shaft.
- Apply a thin coat of grease to entire exposed surface of guide and rack shaft. Apply a coat of grease to inner surface of back-up ring and "O" ring. Install snap ring into groove in rack housing. Attach Installer (926320000 ) to cylinder end of rack shaft and drive back-up ring and oil seal into place using a press.