- Use all new "O" rings, seal rings and oil seals. When replacing, lubricate with power steering fluid before insertion.
- Lubricate bearing surface of side cover. Install 33 roller bearings. Apply grease to bottom of side cover. Install "O" ring to side cover.
- Insert adjusting bolt and plate into "T" slot on top of cross shaft. Using adjusting plates, set cross shaft play to 0-.002" (0-.50 mm). See CROSS SHAFT ADJUSTING PLATE THICKNESS
.
CROSS SHAFT ADJUSTING PLATE THICKNESS
| Plate No. |
In. (mm) |
| 1 |
.077 (1.95) |
| 2 |
.079 (2.00) |
| 3 |
.081 (2.05) |
| 4 |
.083 (2.10) |
| 5 |
.085 (2.15) |
- When installing adjusting plates, place chamfered edge of adjusting plate to contact surface of cross shaft. See Fig 1
. Align cross shaft with side cover.
- Tighten with adjusting bolt. Do not allow bearing to fall off or damage seal ring. Tighten lock nut temporarily. Apply grease to oil seal lip.
- Press oil seal and ball bearing into top cover. Apply grease to "U" packing and lip of oil seal. Press into steering gear. Install "O" ring and seal ring to input worm shaft.
- Install thrust plate, needle bearing, and thrust plate in that order onto input worm shaft. Install "O" ring and seal ring (compressed into shape) into valve housing groove.
- Install input worm shaft to valve housing. Install thin thrust plate, needle roller bearing and thick thrust plate in that order to top cover.
- Using Spanner Wrench (MB990853
), temporarily tighten top cover to valve housing. Make sure thrust plate and needle bearing are aligned.
- Attach spring tension gauge to spanner wrench. Tighten cover to 14-19 lbs. (6.4-8.6 kg). Loosen cover to zero. See Fig 2
. Check input worm shaft for uniform rotation.
- Using Preload Socket (CT-1108
) and an INCH lb. torque wrench, measure and record input worm shaft starting torque. Gradually tighten top cover until input worm shaft starting torque is 1.8-2.7 INCH lbs. (.2-.3 N.m) greater than recorded value.
- Using Spanner Wrench (MB990852
) and torque wrench, tighten valve housing nut without rotating top cover. Again measure input worm shaft starting torque while turning input worm shaft.
- If starting torque is not 2.2-5.6 INCH lbs. (.3-.6 N.m), loosen valve housing nut and repeat steps 11) and 12). Install "O" ring and seal ring to rack piston without forcing.
- Insert rack piston into input worm shaft until piston touches worm shaft end. Rotate worm shaft while aligning ball running surface with ball insertion hole.
- Insert 19 balls into hole by pushing lightly with a brass rod. After installation, ensure ball-to-rack piston clearance is .50" (13.0 mm). See Fig 3
.
- If clearance is excessive, a ball has entered wrong groove. Remove rack piston. Reinstall balls. Insert 7 more balls with grease to keep them from falling.
NOTE:
Do not rotate input worm shaft and rack piston. Balls may enter wrong grooves.
- Insert circulator and holder to rack piston and tighten. Mount gear box in vise. Install valve housing and rack piston. Tighten valve housing. Rotate input worm shaft to move rack piston to center (neutral) position.
NOTE:
Do not force rack piston into housing. Seal ring may be damaged by edge of gear housing.
- Apply a thin coating of automatic transmission fluid to teeth and shaft of rack piston. Apply grease to oil seal lip. Wrap serration of cross shaft with vinyl tape to avoid damage when installing.
- Install cross shaft and side cover to steering gear. To prevent damage to "O" ring during installation, DO NOT rotate side cover when installing.
- Tighten side cover. Using Preload Socket (CT-1108
), measure starting torque of input worm shaft. Adjust starting torque to 4.3-7.8 INCH lbs. (.5-.9 N.m) by turning cross shaft adjusting bolt.
- Tighten lock nut. Make sure valve housing and rack piston unit operates smoothly. Connect cross shaft to pitman arm. Ensure slit on cross shaft tip aligns with groove on pitman arm.