Assembly

1. Install gearbox mounting cushion as follows:
a. Apply weatherstrip adhesive to inside of new cushion.
b. Install and position 0.80 inch from end of cylinder housing. After installing cushion, wipe off any excess adhesive that may have dripped inside cylinder housing.
c. Apply thin coat of grease to inside of rack end bushing. Do not fill bushing slots with grease as they must remain open to serve as air passages.
2. Install rack end bushings, aligning round projections on bushings with holes in housing.
3. Install steering into cylinder housing.
4. Drive steering pinion shaft into gear housing using suitable tools.
5. Install snap rings and seals.
6. Install rack guide and spring, then the guide screw and locknut. Install new lock washer in groove on steering rack.
7. Hold steering rack with wrench and tighten rack end to specifications.
8. Stake four sections of lock washer with suitable roll pin drift and mallet.
9. Apply grease to circumference of rack end housing, then coat rack end groove and inside of boot with silicone grease.
10. Install boots in rack end with tube clamps.
11. Install boot band with rack in straight-ahead position (right and left tie rods are equal in length). Tabs should face up and slightly forward.
12. Install new boot bands on boot and bend both sets of locking tabs, then lightly tap on doubled-over portions to reduce their height.
13. Slide rack right and left to be certain boots are not deformed or twisted, then install right and left tie rod end on right and left rack end.
14. Install steering gear and tighten fasteners to specifications.