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

Assembly Procedure

  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).
    Fig 1: Installing Worm Shaft To Rack Piston Outside Of Steering Gear Housing
    G01645943Courtesy of GENERAL MOTORS CORP.

    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 sliver rack piston balls. Install the black and the sliver 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.
    Fig 2: Installing Rack Piston Balls Into Rack Piston
    G01645944Courtesy of GENERAL MOTORS CORP.
  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).
    Fig 3: Installing Remaining Rack Piston Balls Into Ball Guide
    G01645945Courtesy of GENERAL MOTORS CORP.
  8. Install the ball guide (3) to the rack piston (2).
  9. Install the ball guide clamp (4).
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  10. Install the screws (5).

    Tighten 

    Tighten the screws (5) to 6 N.m (53 lb in).

  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 4: Inserting J 21552 Into Bore Of Rack Piston
    G01645946Courtesy of GENERAL MOTORS CORP.
  12. Install the flat races (2, 4) and the thrust bearing (3) onto the worm shaft (1).
    Fig 5: Installing Flat Races & Thrust Bearing Onto Worm Shaft
    G01645947Courtesy 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 (700 GEAR) .
  15. Install the rack piston (2) to the worm (4) from J 21552  using J 8947  to compress the seals.
    Fig 6: Installing Rack Piston To Worm
    G01645948Courtesy of GENERAL MOTORS CORP.
  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 

    Tighten the rack piston plug to 150 N.m (111 lb ft).

  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 install onto the steering gear housing.

  21. Install the pitman shaft seals and bearing. Refer to PITMAN SHAFT SEALS AND BEARING REPLACEMENT - OFF VEHICLE (700 GEAR) .
  22. To adjust the steering gear; refer to one of the following procedures:
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