Assembly & Adjustment
- Press bearing onto pinion and install snap ring and thrust washer. Install new "O" rings on rack bushing and press bushing into housing making sure that tabs on bushing fit correctly into slots in housing. Grease rack with Calypsol D 4024-OK grease or equivalent. Insert rack into pinion side of housing using care not to damage rack bushing with rack teeth. Grease pinion using same grease as for rack and install pinion with bearing.
- Install new "O" ring in pinion nut and install nut using suitable tool (5119). Torque to 18±1.5 ft.lbs. (2.5±.2 mkg). Fill cavity on top of nut with grease and install dust seal. Install new "O" ring on rack damper piston, grease piston and install piston and spring. Install, but do not tighten rack damper cover (tool 5119). Using torque gauge, crank rack back and forth between end positions. Torque should be 5-15 INCH lbs. (5.8-17.3 cm kg). To increase torque, screw in rack damper cover. Lock cover in correct position with cotter pin and install dust cover.
- Crank out rack fully and fill rack tooth spaces with Calypsol D 4024-OK grease or equivalent. Crank rack in and then out again and repeat grease application. Approximately 1 oz. (25 g) of grease should be used. Install tie rods using new lock washers and bend washer to lock rod in place. Install rubber bellows.
Courtesy of VOLVO CARS CORPORATION