Steering Rack Removal

Fig. 4 Removing rack from gear case:

1. Remove boot wires and clips. Slide boots toward tie rod end.
2. Unbend tie rod lock washers and remove tie rods. Mark left and right tie rods.
3. Remove rack plunger and pinion assembly as described under Steering Pinion.
4. Remove rack from gear case as shown in Fig. 4.



Inspection

1. Inspect steering rack for deflection and rack teeth for wear or damage. Rack deflection should not exceed .016 in.

Assembly

1. Apply a suitable lithium based grease to rack teeth surface.
2. Install rack into steering gear case, in opposite direction of removal.
3. Install pinion assembly and plunger assembly as described under ``Steering Rack'' Removal.

Fig. 5 Ensuring that rack side mount is positioned:

4. Install boot to steering rack housing, ensuring that rack side mount is positioned as shown in Fig. 5.
5. Install tie rods as described under ``Steering Rack.''

Fig. 6 Removing pinion bearing:

PINION BEARING
Removal

1. Remove rack from steering gear case as described under ``Steering Rack Removal.''
2. Remove pinion bearing using tools J-34839 and J-6125-1B, as shown in Fig. 6.



Inspection

Check pinion bearing for wear or damages. Replace if found defective.

Assembly

1. Apply a suitable lithium based grease to pinion bearing rollers.
2. Press fit pinion bearing into gear case using tool J-934840 or equivalent.
3. After bearing has been installed, ensure that rollers are installed properly.
4. Refer to ``Steering Rack Assembly'' for steering rack installation.

Fig. 7 Removing rack bushing:

RACK BUSHING
Removal

1. Remove rack from steering gear case as described under ``Steering Rack Removal.''
2. Remove snap ring. When removing bushing, be careful not to pull bushing while holding gear case in vise as the housing may come off gear case.
3. Remove bushing from rack housing using tool J-34869 or equivalent, Fig. 7.

Inspection

Inspect bushing for wear or damage and replace if necessary.

Fig. 8 Installing rack bushing:

Assembly

1. Apply a suitable lithium based grease to inner surface of bushing.
2. Using tool J-34868 or equivalent, install bushing into rack housing, ensuring bushing to housing clearance is as shown, Fig. 8.
3. Install snap ring.
4. Install steering rack assembly as described under Steering Rack Assembly.