Assembly

1. Prior to reassembly. Clean all gearbox components in a suitable solvent.
2. With bearing press tool No. 09565-21000, or equivalent, press fit bearing to pinion.
3. Install snap ring on pinion.
4. Apply grease to rack, pinion, bushing, needle roller bearing and other moving surfaces. Do not seal air passage in housing bushing with grease. Use recommended multi-purpose grease SAE J310a, NLGI grade No. 2 EP.
5. After inserting rack into gear housing from left side, install pinion gear in mesh with rack.
6. Select and install appropriate type of snap ring to minimize play in axial direction on pinion.
a. Blue -0.063 inch.
b. White -0.066 inch.
c. Yellow -0.069 inch.
7. Apply grease to lip of oil seal before installing new oil seal in gearbox.
8. Install support yoke, cushion rubber, spring and yoke plug to pinion gearbox. Apply grease to cupped portion of support yoke.
9. Adjust yoke plug with rack in straight ahead position, with socket tool No. 09565-21000, or equivalent. Torque yoke plug to 8 ft. lbs. and then back off 30°-60°. Secure yoke plug with locknut after applying sealer between locknut and housing, Torque to 37-52 ft. lbs.
10. Install tie rod end and bellows. Use and stake a new locking plate at each end.
11. To measure combination preload of pinion (with bellows and grease), turn pinion at rate of one revolution every 4-6 seconds with socket tool No. 09565-11100, or equivalent. Rack starting force should also be measured.
12. Total pinion preload is as follows:
a. ±180° or less from straight forward position. 3.5-9.5 inch lbs.
b. ±180° or more from straight forward position. 2.4-14 inch lbs.
13. Rack starting force is 11-66 ft. lbs.
14. If measured values are out of specification, replace cushion rubber and yoke spring and readjust.