Disassembly/Assembly

Fig. 4 Rack & Pinion Manual Steering Gear Assembly.:

Disassembly
1. Place steering assembly in suitable vise, then mark position of tie rod and rack end for reference during assembly. Remove tie rod ends, Fig. 4.
2. Remove clip and clamp, then remove rack boot.
3. Remove rack end dust seal, then remove claw washer. Remove rack end using suitable tool and a wrench. Use caution not to scratch outside of rack with wrench.
4. Remove rack guide spring cap locknut, rack guide spring cap and spring.
5. Remove rack guide, dust cover, locknut and pinion bearing adjusting screw.
6. Pull rack from rack housing side and align rack notched portion with pinion. Remove pinion, upper bearing and washer.
7. Remove rack from pinion side, using caution not to rotate rack as it is being removed.

Inspection & Assemble
1. Inspect rack boot, rack end dust seal and rack clamp for damage and wear.
2. Check for excessive play in rack end ball joint.
3. Inspect rack guide for damage or wear.
4. Inspect pinion tooth surface for damage or wear. Check oil seal and dust cover for damage or wear.
5. On 1989-90 models, if pinion oil seal is to be replaced, install new oil seal until it protrudes .02 inch (.5mm) from pinion bearing adjusting screw tip.
6. On all models, to replace pinion upper bearing, remove and install using suitable puller and press. Check to ensure spacer is installed before installing bearing.
7. To replace lower bearing, heat rack housing to above 176°F, then tap bearing from shaft. Heat housing again when installing bearing.
8. Measure rack runout using dial indicator. Runout should be no more than .012 inch (.3mm).
9. Apply suitable grease to pinion lower bearing, and rack bushing. Install rack into rack housing. Position rack notched area so that pinion can be installed.
10. Apply grease to pinion bearing and tooth surfaces, then install pinion and spacer.
11. Install pinion bearing adjusting screw and adjust preload to 3.2 inch lbs. on all vehicles. Loosen adjusting screw until preload is 2-2.9 inch lbs. on all vehicles.
12. Install adjusting screw locknut and torque to specifications. Check for pinion preload of 2.0-2.9 inch lbs. on 1989-90 models, or 1.3-2.2 inch lbs. on 1991-92 models.
13. Apply grease to rack guide, then install spring and rack guide spring cap. torque spring cap to 43 inch lbs. Check for preload of 5.2-12.2 inch lbs. on 1989-90 models, 5.2-10.4 inch lbs. on 1991-92 models. Adjust by rotating spring cap.
14. Install locknut and tighten to specifications. Recheck preload as described in step 13.
15. Install dust cover and claw washer, aligning claw on washer with rack groove, then torque rack end to specifications. on all models except Tercel Sedan, or 43 ft. lbs. on Tercel Sedan. Stake claw washer in position
16. Install rack end seal and dust boot. Check to ensure tube hole is not blocked.
17. Install rack boot clamp with tapered edge toward tube side. Install rack boot clip.
18. Install tie rod end aligning marks made during disassembly.