Assembly Procedure

WARNING: This page is about a different car, the 2003 GMC Sonoma, 2003 GMC Jimmy, 2003 Chevrolet S10 Pickup, and 2003 Chevrolet Blazer. However, it is still accessible from the selected car via links, so may be relevant.

Install the O-ring seal (3) and the teflon ring (2).
Lubricate both parts with power steering fluid.
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.

Fig 1: Installing Worm Shaft To Rack Piston Outside Of Steering Gear Housing
Courtesy of GENERAL MOTORS CORP.
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.
Lubricate the rack piston balls with power steering fluid.
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.

Fig 2: Identifying Ball Return Guide Hole & Worm Shaft
Courtesy of GENERAL MOTORS CORP.
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).

Fig 3: Installing Remaining Rack Piston Balls Into Ball Guide
Courtesy of GENERAL MOTORS CORP.
Install the ball guide (3) to the rack piston (2).
Install the ball guide clamp (4).
NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
Install the screws (5).
Tighten

Tighten the screws (5) to 6 N.m (53 lb in).
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 4: Installing Ball Guide, Ball Guide Clamp & Screws To Rack Piston
Courtesy of GENERAL MOTORS CORP.
Install the flat races (2, 4) and the thrust bearing (3) onto the worm shaft (1).

Fig 5: Install Flat Races & Thrust Bearing Onto Worm Shaft
Courtesy of GENERAL MOTORS CORP.
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.
Install the spool valve. Refer to STEERING GEAR VALVE REPLACEMENT - OFF VEHICLE (700 GEAR) .
Install the rack piston (2) to the worm (4) from J 21552 using J 8947 to compress the seals.
Hold J 21552 tightly against the worm shaft (4).
Turn the stub shaft clockwise until the rack piston (2) is seated on the worm shaft (4).
Remove J 21552 from the rack piston (1).

Fig 6: Rack Piston & Warm Shaft
Courtesy of GENERAL MOTORS CORP.
Install the rack piston plug (1).
Tighten

Tighten the rack piston plug to 150 N.m (111 lb ft).
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.
Install the pitman shaft seals and bearing. Refer to PITMAN SHAFT SEALS AND BEARING REPLACEMENT - OFF VEHICLE (700 GEAR) .
To adjust the steering gear; refer to one of the following procedures:
- WORM THRUST BEARING PRELOAD ADJUSTMENT - OFF VEHICLE (700 GEAR)
- PITMAN SHAFT OVER-CENTER PRELOAD ADJUSTMENT - OFF VEHICLE (700 GEAR)

Fig 7: Removing Pitman Arm & Pitman Shaft Boot From Steering Gear

Courtesy of GENERAL MOTORS CORP.