Disassembly/Assembly

Fig. 6 Manual Rack & Pinion Steering Assembly:

DISASSEMBLY

1. Place steering gear assembly in a suitable soft-jawed vise.
2. Remove outer tie rod ends and locking nuts, then place tie rod ends in a suitable soft-jawed vise and remove dust covers using a hammer and screwdriver.
3. Remove bellows clips, bands, and bellows.
4. Separate tab washers from inner tie rods using a chisel, then remove inner tie rods and tab washers.
5. Remove rack support cover lock nut, rack support cover, rack support spring, cushion rubber and rack support.
6. Remove top plug lock nut, top plug, pinion oil seal, pinion collar, then the pinion and bearing assembly.
7. Remove pinion bearing from pinion using a suitable press and steering/pinion gear remover/installer MB990783 or equivalent.

Fig 3 Rack Removal Direction:

8. Remove rack from gear housing by pulling in direction shown.
CAUTION: If rack is pulled from housing in wrong direction, rack bushing in gear housing may be damaged by rack threads.
9. Remove rack bushing from rack housing.
10. Inspect rack support for uneven wear or damage, rack support spring for deterioration, rack pinion tooth surfaces for wear or damage, pinion bearing for noise, uneven rotation or damage and rack bushing for damage. Replace as necessary.

ASSEMBLY

1. Apply Mopar multi-mileage lubricant 2525035 or equivalent to rack tooth surfaces, rack bushing and pinion needle bearing in rack housing.
2. Install rack bushing, then the rack into gear housing opposite of removal.
3. Press pinion bearing onto pinion using steering/pinion gear remover/installer MB990783 or equivalent.
4. Apply multi-mileage lubricant to toothed surface of pinion, install pinion and bearing assembly into housing, then the pinion collar.
5. Press oil seal into top plug, apply semi-drying sealant to threaded portion of top plug, install top plug, then the top plug locking nut and torque to specifications.
6. Apply multi-mileage lubricant to surface of rack support that contacts rack, then install rack support to rack housing.
7. Apply multi-mileage lubricant to inner side of rack support spring, then install rack support spring to rack housing.

Fig 3 Rack Removal Direction:

8. Install rubber cushion to rack support cover, apply a coating of semi-drying sealant to threaded part of rack support cover, install rack support cover to rack housing, then the lock nut.
9. With rack placed in center position, torque cover to specifications.
10. In a neutral position, rotate pinion shaft at a rate of one revolution every 4 to 6 seconds using preload socket CT-1108 and a suitable torque wrench. Return rack support cover 30-60° and adjust torque as follows:
a. From 0-90°, torque should be 5-11 lb-in, from 90-650°, torque should be 2-9 lb-in.
11. When adjusting, set at highest value, ensure that there is no ratcheting or catching when operating rack towards shaft direction.
12. If specified values cannot be obtained, check rack support cover components and replace as necessary.
13. Install and torque locking nut to 36-51 lb-ft.
14. Install tab washers and inner tie rods, then torque inner tie rods to 58-72 lb-ft.
15. Secure inner tie rods by bending tab washers onto tie rod stepped portions.
16. Pack tie rod bellows lock groove with suitable silicone grease, install bellows into position and ensure that they are not twisted, then the clips and bands.
17. Fill inside and lip of dust covers with multi-mileage lubricant, apply semi-drying sealant to dust covers, then press dust covers onto tie rod ends using front axle base MB990776-A or equivalent.
18. Install outer tie rod end locknuts, then the tie rod ends.
19. Adjust so that length between outer lip of bellows and inner side of tie rod end is 7.68-7.76 inches, then torque tie rod end locknuts to 36-40 lb-ft and recheck length.