Assembly

Fig. 1 Exploded View Of Type 4--Rack & Pinion:

Reassemble rack and pinion in reverse order of numbered sequence shown, noting the following.

1. Apply Dextron or Dextron 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. Use seal ring installer MB991317 or equivalent to compress pinion seal rings during installation.
4. Install back-up washer and oil seal into housing using oil seal installer MB991097 and oil seal installer attachment MB991098 or their equivalents.
5. Install pinion needle bearing using bearing and oil seal installer MB991100 and bearing and oil seal installer attachment MB991102 or their equivalents. Set scribed side of bearing in installer.
6. Install oil seal to rack bushing using oil seal installer MB991097 or equivalent.
7. Cover rack with a vinyl bag (supplied in repair kit) and secure with vinyl tape, then insert slowly into housing.
NOTE: Ensure that vinyl bag is free of wrinkles and that bag is not damaged after installation.
8. 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.
NOTE: Circlip end should be visible through notched hole of housing.
9. Wrap vinyl tape around pinion teeth, then install seal using a suitable pipe.
10. Secure inner tie rods by bending tab washers onto tie rod stepped portions.
NOTE: Align tab washer pawls with rack grooves.
11. Apply semi-drying sealant to threaded section of end plug, install end plug, then stake at two points with a punch.
12. Apply semi-drying sealant to threaded section of rack support cover, then with rack in center position, attach rack support cover to housing and torque to specifications using torque wrench socket MB990607-A or equivalent. Back-off cover 10°, then torque locknut to specifications.
13. Fill outer tie rod end dust cover inner side and lip with multi-mileage lubricant.
14. Adjust tie rod length between end of bellows and inner side of tie rod locknut to 6.1 inches.
15. Confirm total pinion preload, refer to Transmission and Drivetrain/Differential.