Assembly

Fig.12 Exploded View Of Rack And Pinion Steering Gear:

Assemble rack and pinion in reverse order of numbered sequence shown, noting the following:
1. Apply Dexron or Dexron II automatic transmission fluid to O-rings, seal rings, entire surface of oil seals and rack.
2. Apply Mopar multi-mileage lubricant or equivalent to ball bearings, entire surface of needle bearings, rack teeth and pinion teeth.
3. Using suitable tools, press back-up washer and oil seal, pinion needle roller bearing and ball bearing and housing oil seals into housing.
4. Cover rack teeth with rack installer tool No. MB991212, or equivalent.
5. Apply Dexron or Dexron II to installer, then match oil seal center with rack to prevent retainer spring from slipping.
6. Slowly insert rack from power cylinder side.
7. Wrap vinyl tape around end of rack, then install rack bushing and stopper. Push stopper in until circlip groove of stopper is aligned with notched hole of housing, then install circlip while turning stopper. Circlip end should be visible through notched hole of housing.
8. Using suitable tools, press oil seal and ball bearing into valve housing.
9. Use seal ring installer tool No. MB991317, or equivalent, to compress pinion seal rings during installation.
10. Wrap vinyl tape around pinion teeth, then install seal using a suitable pipe.
11. Secure inner tie rods by bending tab washers onto tie rod stepped portions.
12. Apply semi-drying sealant to threaded section of rack support cover, then secure temporarily with locknut.
13. Apply semi-drying sealant to threaded section of end plug, install end plug, then stake at two points with a punch.
14. Fill outer tie rod end dust cover inner side and lip with multi-mileage lubricant.
15. Adjust tie rod length between end of bellows and inner side of tie rod locknut to the following specifications:
a. Stealth AWD models, distance should be 7.66 inches.
b. Stealth FWD models, distance should be 7.54 inches.
c. On 1994 Laser and Talon AWD models, distance should be 7.07-7.15 inches.
d. On 1994 Laser and Talon FWD models, distance should be 7.22-7.30 inches.
e. On 1995-96 Talon models, distance should be 4 inches.