Assembly & Adjustment
- Oil all parts prior to assembly with 20W-50 engine oil. Install new rack bushing so that locks align with gear housing slots, using driver tool (2993). Install pinion lower bearing using driver tool (5048). Install pinion with upper bearing, but no shims, in housing. Install pinion spacer sleeve and cover with gasket but no seal. Use a dial indicator to measure pinion end play and record for later use. Remove pinion assembly.
- Insert rack in gear housing from pinion side using care that rack teeth do not damage rack bushing. Apply a non-hardening gasket compound to pinion cover seal and install seal in cover using suitable driver (2734). Calculate required pinion shim thickness by adding 0.004 - 0.010" (0.10 - 0.25 mm) to pinion end play previously measured. This will give correct amount of pinion preload. Install pinion, shims and spacer sleeve with shims between upper bearing and spacer sleeve. Install pinion cover with gasket and seal.
- Place rack damper piston in housing without "O" ring or ' spring. Using straight edge and feeler gauge, measure end play between end of piston and housing (see Fig 1 ). Measure thickness of gasket and calculate shim thickness required to obtain a total thickness, between gasket and shim, of 0.001 - 0.006" (0.02 - 0.15 mm) greater than the measured piston end play to obtain correct preload. Install spring and "O" ring in piston, install shims, gasket and cover.
- Using suitable torque gauge (5053), crank rack back and forth from one end to the other. Torque reading should be 8-14 INCH lbs. (9-17 cmkg). Install pinion side tie rod and punch ball joint edge into rack groove.NOTE: When installing old tie rod, place a thin shim between ball joint and rack shoulder so unused portion of ball can be used for punch locking.
- Install pinion side rubber bellows with inner clamp only. Install lock nut and ball stud. Repeat procedure for other side of gear and adjust both rods to the same length within 0.08" (2 mm). Use a suction gun to inject 6.75 ozs. (200 cc) of 20W-50 engine oil through outer end of pinion side rubber bellows. Install outer clamps on bellows.