323 L4-1600 1597cc (1986)
Fig. 10 Disassembled view of variable gear ratio manual steering gear. 1986-88 323
W/Variable Gear Ratio Steering Gear
1.
Before assembling, the following parts should be coated or packed with suitable grease:
a. Lower bearing.
b. Pinion bearing and teeth.
c. Inside gear housing.
d. Oil seal lip.
e. Pressure pad sliding part and rear surface.
2.
Press lower bearing into housing, Fig. 10.
3.
Install rack busing in rack housing using a suitable piece of wood. Ensure three bushing lock points are aligned.
4.
Install mounting rubber.
5.
Install rack in opposite direction of removal.
6.
Install pinion shaft with rack positioned so that notch on teeth edge of rack is at center of pinion.
7.
Install upper bearing.
8.
Push oil seal in pinion plug, then install pinion plug with oil seal on pinion shaft.
9.
Adjust pinion preload to 1.74 inch lbs. using a suitable torque wrench or to 5-9 ounces using a spring scale by adjusting pinion plug. Before
measuring pinion preload, rotate pinion to left and right to seat bearing.
10.
Install locknut and torque to 51-65 ft.lbs.
11.
Apply a coat of suitable sealant to threads of adjustment cover, then install pressure pad, spring, adjustment cover and locknut. Ensure pressure
pad is correctly installed.
12.
Torque adjustment cover to 7.2 ft.lbs., then back off cover approximately 15° and torque locknut to 43-54 ft.lbs.
13.
Measure pinion preload. When pinion is within 90° of neutral position, preload should measure .87-1.21 inch lbs. If measuring with a spring scale,
preload should measure 35-49 ounces. When pinion is in any other position, preload should measure 20 inch lbs. or less. If measuring with a
spring scale, preload should measure 81 ounces or less.
14.
Apply soapy water to inside of rubber mount, then install rubber mount on steering column.
15.
Install tie rod washers and tie rod. Torque tie rod to 58-72 ft.lbs. Align washer with rack groove, then crimp washer to secure.
16.
Install dust cover on pinion groove, then the new boot and wire. Wrap wire twice around boot and twist end 4-5 times around.
17.
Install tie rod end, aligning marks made during disassembly.
