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Steering Gear: Reassembly

  1. Lubricate all "O" rings, seals, sleeves and moving parts before installation. Install seal and "O" ring to end housing.
  2. Install new center feed porting adapter to porting ring. Position ring to allow conical adapter to engage seat on cylinder. Tighten to specification.
  3. Install rack seal over rack teeth. Install anti-extrusion ring to recess in back of rack seal. Lubricate inside of rack housing and grease rack. Insert rack into rack housing with firm steady pressure until seal seats against abutment face.
  4. Ensure piston ring collapses and enters rack housing without damage. Install new seal, washer and snap ring to pinion housing. Install new pinion valve seal to pinion shaft (located against pinion bearing).
  5. Lubricate pinion shaft, piston seals, and bearing. Carefully install pinion shaft in pinion housing. Tap gear end of shaft lightly to properly seat.
  6. Grease pinion teeth and small pinion journal. Install pinion, housing, and new gasket to rack housing. Ensure rack teeth and pinion teeth mate correctly.
  7. Ensure pinion housing ports are correctly aligned so cylinder-to-valve pipes can be installed. Install seals to end housing.
  8. Install end housing-to-rack housing. Screw locking ring into end housing just enough to hold mounting feet in parallel alignment.
  9. With end housing and mounting feet in alignment, tighten locking ring. Install rack plunger, spring, adjusting plug and lock nut. Tighten adjusting plug while moving rack through full stroke, until rack is hard to move. See Fig 1 .
    Fig 1: Adjusting Rack End Play (XJS)
    G41894Courtesy of JAGUAR CARS LTD.
  10. Back off adjusting nut just enough to obtain a smooth rack movement (approximately 1/8 turn). Tighten lock nut while holding adjusting plug from turning.
  11. To complete reassembly, reverse disassembly procedure. Place 1-2 oz. of grease into each bellows. Replace plug in rack plunger adjusting plug with a grease fitting. Grease rack plunger. Remove grease fitting. Install plug.
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