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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 729 (Power Steering System) >> Repair Instructions >> Rack Piston & Worm Shaft Replacement - Off Vehicle (700 Gear) >> Assembly Procedure

Assembly Procedure

WARNING: This page is about a different car, the 2002 GMC Safari and 2002 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the O-ring seal (3) and the teflon ring (2).
  2. Lubricate both parts with power steering fluid.
  3. Install the worm shaft (14) to the rack piston (4) outside of the steering gear housing (9). Fully seat the worm shaft to the rack piston.
  4. Align the worm shaft spiral groove with the rack piston ball return guide hole (1).

    Important:  Improper rack piston ball installation may result in personal injury. The black rack piston balls are smaller than the silver rack piston balls. Install the black and the silver rack piston balls alternately into the rack piston and the ball guide to maintain the rack piston to the worm shaft preload.

  5. Lubricate the rack piston balls with power steering fluid.
  6. Insert the rack piston balls through the ball return guide hole (1) while turning worm shaft (2) counterclockwise in order to install the rack piston balls into the rack piston.
  7. Install the remaining rack piston balls (3) into the ball guide (1) using grease at each end (2) to retain the rack piston balls (3).
  8. Install the ball guide (3) to the rack piston (2).
  9. Install the ball guide clamp (4).
  10. Install the screws (5). Tighten the screws (5) to 58 N.m (43 lb ft).
  11. Insert J 21552  into the bore of the rack piston while turning the worm shaft counterclockwise. The turning of the worm shaft forces the rack piston onto J 21552  . The rack piston balls remain in place.
    Fig 1: Installing Rack Piston
    G02501286Courtesy of GENERAL MOTORS CORP.
  12. Install the flat races (2, 4) and the thrust bearing (3) onto the worm shaft (1).
    Fig 2: Installing Flat Races & Thrust Bearing Onto Worm Shaft
    G02501287Courtesy of GENERAL MOTORS CORP.
  13. Install the worm shaft (4) to the steering gear housing (3).

    Important:  Do not adjust the worm shaft until all components are installed onto the steering gear housing.

  14. Install the spool valve. Refer to Steering Gear Valve Replacement - Off Vehicle  .
  15. Install the rack piston (2) to the worm (4) from J 21552  using J 8947  to compress the seals.
  16. Hold J 21552  tightly against the worm shaft (4).
  17. Turn the stub shaft clockwise until the rack piston (2) is seated on the worm shaft (4).
  18. Remove J 21552  from the rack piston (1).
  19. Install the rack piston plug (1). Tighten the rack piston plug to 150 N.m (111 lb ft).
    Fig 3: Installing Rack Piston Plug
    G02501288Courtesy of GENERAL MOTORS CORP.
  20. Install the housing end plug. Refer to Steering Gear Housing End Plug Replacement - Off Vehicle  .

    Important:  Do not adjust the pitman shaft until all components are installed onto the steering gear housing.

  21. Install the pitman shaft seals and bearing. Refer to PITMAN SHAFT SEALS & Bearing Replacement - Off Vehicle (700 Gear)  .
  22. To adjust the steering gear; refer to one of the following procedures:
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