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Steering Gear: Reassembly

  1. If rack bushing was removed, use Bushing Installer (09943-78210) to install NEW rack bushing. Bushing must be positioned .04-.08" (1.0-2.0 mm) below surface of housing.
    CAUTION: Inside diameter of rack bushing is coated with special coating. DO NOT damage coating when installing bushing.
  2. Install rack bushing retaining snap ring. If needle bearing was removed, use Bearing Installer (09943-88211] to install needle bearing.
  3. Install rack in the housing. Use care not to damage coating on rack bushing during installation. Install pinion in housing.
  4. Install case seal and pinion bearing plug. Using Socket (09944-28210), tighten pinion bearing plug to specification. See TORQUE SPECIFICATIONS TABLE  at end of article. Install dust cover.
  5. Install rack plunger, spring and rack adjusting screw. Tighten rack adjusting screw until snug. Back off adjusting screw 90 degrees. Install INCH lb. torque wrench and Socket (09944-18211) on pinion.
  6. Rotate pinion and note rotating torque. Adjust rack adjusting screw until rotating torque is 9 INCH lbs. (1.2 N.m). Ensure rack moves smoothly. Once adjustment is correct, install cap on rack adjusting screw.
  7. Install lock washer and inner tie rods on rack. Tighten inner tie rod nut to specification. See TORQUE SPECIFICATIONS TABLE  at end of article. Bend lock washer over on flat area of inner tie rod.
  8. Apply grease on boot-to-inner tie rod areas. Install boot clamp and boot. Boot clamp wire must be wrapped around boot twice and ends twisted together. Ensure boot seats in grooves on housing and is not twisted. Install spring clip.
  9. Install nut and tie rod end. Ensure reference marks on tie rod end and inner tie rod are aligned. Tighten nut to specification. See TORQUE SPECIFICATIONS TABLE  .
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