Assembly & Adjustment
- Set steering box in horizontal position in padded vise, with pinion flange on top. Insert lower pinion bearing, using a suitable driver (A. 74219). Replace bushing in steering box. Slide rack into position with smooth side facing pinion seating. When rack is fully in place, turn teeth to face axis of pinion seating.
- Insert pinion, ensuring it mates properly with rack teeth, then install upper pinion bearing. Apply force to pinion to eliminate axial play, then with a suitable measuring device, measure distance "A" as shown in illustration. To this measurement, add 0.001 - 0.005" (0.025 - 0.13 mm). This will give the total shim thickness to be used. Remove tool, install shim, cover plate, and oil seal. Check turning torque of pinion. It should be 0.3 ft. lb. (.04 mkg) or less.
- Set rack to center position, insert rack damper yoke in its seat, install cover plate (without shims) and turn pinion 180° in both directions to settle rack and yoke. Measure gap between rack yoke cover plate and mounting surface ("B" as shown in illustration). To this measurement, add 0.002 - 0.005" (0.05 - 0.13 mm). This will give total shim thickness to be used. Remove cover, insert spring, "O" ring, shim (coated with liquid adhesive), and cover. Tighten bolts as required. Ensure ground wire is in place.
- Screw ball joint ring nuts onto rack to end of threaded portion. Assemble springs and socket. Lubricate ball pins with suitable oil, and assemble to rack. Install adjustable ball joint heads and tighten until a force of 1.5-3.75 ft.lbs. (0.2 - 0.5 mkg) is required to turn the pins. Lock heads in position with nuts, then stake-lock the nut collars and ball heads. Replace rubber dust boots and clamp in place. Ensure clamp screws are positioned such that they will be accessible when gear assembly is installed in vehicle. Fill gear with 4.75 oz. (140 cc) of suitable gear oil.NOTE: Lubricate dust boots with a silicone spray and be sure they are not twisted after installation.