Modified Zf Rack & Pinion Steering

Fig. 5 Modified ZF rack & pinion steering gear:

1. Pull rack bushing from steering housing, Fig. 5.
2. Remove snap ring and thrust washer from pinion and press off ball bearing.

Fig. 6 Removing needle bearing:

3. Drive needle bearing out of steering housing using tool P362, Fig. 6.
4. During assembly fill steering housing with multipurpose grease.

Fig. 7 Measuring bearing depth:

5. Drive needle bearing into housing with tool P362 until depth from top edge of steering housing to top of needle bearing is .12 inch (3 mm), Fig. 7.
6. Install pinion bearing.

Fig. 8 Measuring distance from ball bearing to housing contact surface:

7. Measure distance from ball bearing to contact surface of housing, Fig. 8. Use shims to adjust the freeplay between the housing cover and ball bearing. Maximum freeplay is .002 inch (.05 mm).

Fig. 9 Measuring distance between pressure block and housing contact surface:

8. Measure distance between pressure block and contact surface of housing, Fig. 9. The total thickness of all shims installed should be .008 inch (.2 mm) less than the distance measured in step 8.
9. Check preload over entire working length of steering rack. The total torque required should not exceed 5-7 inch lbs. (6-8 cmkp).