Assembly

Fig. 1 Disassembled view of Saginaw rack & pinion steering gear. Dodge Omni & Plymouth Horizon & 1982---88 Charger & Turismo:

Fig. 3 Removing pinion lower bearing:

Fig. 4 Removing & installing upper pinion bushing & seal:

Fig. 5 Inner rack seal, rack & piston ring installation:

1. Align breather tube with mark on housing, then install grommet so that tabs lock.
2. Place O-rings on cylinder lines and assemble cylinder lines to housing. Tighten fittings finger tight to ensure proper alignment, then torque fittings to 18 ft. lbs.
3. Install upper pinion bushing into housing, then install pinion seal with seal lip facing upward.
4. Install pinion shaft lower bearing into housing, using a suitable socket to press on bearing outer race. Use care to cock bearing in housing. Install retaining ring and position large lug of ring as shown.
5. Install piston ring on rack. Use care not to damage piston ring during installation.
6. Place card stock around rack teeth. Slide inner rack seal over protector and onto card stock with seal lip facing piston. Slide seal and card stock over rack teeth, then remove card stock and bottom seal on rack piston.
7. Slide rack and seal into housing, tap rack with a soft faced mallet to seat seal.
8. Coat seal with power steering fluid, then position seal protector over end of rack and install bulkhead. Use care not to damage seals when installing bulkhead.
9. Install bulkhead retaining ring. Ensure that open end of ring is approximately 1-2 in. from access hole. Also ensure that retaining ring is properly seated.

Fig. 6 Installing valve & pinion assembly:

Fig. 7 Installing stub shaft bearing & seals:

10. Install seal rings on valve body, if removed. If a condition of reduced power assist is encountered when the engine is started cold, it can be caused by improper rack and pinion valve rings. The proper rings are colored green. Any other color ring should be replaced by using Repair Package No. 5205297. Wear marks in the housing valve bore are considered to be normal and do not necessitate replacement of the housing.
11. Center rack in housing, then install pinion shaft and valve assembly so that flat on stub shaft will be aligned with mark on housing when assembly is fully seated.
12. Install stub shaft bearing, seal, dust seal and retaining ring. While holding stub shaft in position, torque locknut to 26 ft. lbs..
13. Install rack bearing, spring and adjuster plug. Turn adjuster plug clockwise until it bottoms, then back plug off 40 to 60 degrees. Install locknut and torque to 50 ft. lbs. while holding adjuster plug in position.

Fig. 8 Tightening tie rod housing:

Fig. 9 Staking tie rod housing to rack flats:

Fig. 10 Securing bellows inner clamp:

14. Install tie rod assembly on rack. While holding rack in position with a wrench, torque tie rod housing to 70 ft. lbs.. If rack is not held in position when tightening tie rod housing, damage to rack or pinion teeth may result.
15. Support rack and housing, then stake tie rod housing to rack flats. Using a feeler gauge check clearance between stakes and rack flats. Clearance must not exceed 0.010 inch.
16. Install shock damper over tie rod housing.
17. Align breather tube with marks made during disassembly, then install bellows with over housing lip with hole in bellows aligned with breather tube. Position inner clamp on bellows, then secure clamp using tool No. C-4124.
18. Position bellows outer clamp and jam nut on tie rod. Install tie rod end in the same position as removed. Torque jam nut to 50 ft. lbs., then install outer bellows clamp. Ensure bellows is not twisted.