323 L4-1600 1597cc (1986)
9.
Remove oil seal, O-rings and seal ring from rack assembly, then the rack assembly from gear housing as shown, Fig. 20.
10.
After removing snap ring on all wheel drive models, remove inner guide and oil seal from rack on all models using a suitable tool. Also on 4 wheel
drive models, remove O-ring located between inner guide and oil seal.
11.
Remove dust cover, oil seal and lever from valve case.
12.
Remove valve cast attaching screws, then the valve case.
13.
Remove control valve bolt, control valve and O-ring from valve case.
14.
Remove valve case gasket and spacer, then the bearing from gear housing using a suitable tool.
15.
Remove housing cover locknut and housing cover, then pull pinion shaft assembly out from lower bearing side.
16.
Remove mounting bracket and mounting rubber from gear housing.
Assembly
1.
On 2 wheel drive models, apply suitable lubricant to inner guide, then install inner guide and oil seal in rack housing using a suitable tool. Use
caution not to damage inner surface of rack housing.
2.
On all wheel drive models, install inner guide as follows:
a. Install oil seal, O-ring and snap ring to inner guide.
b. Coat oil seal and O-ring with transmission fluid.
c. Push inner guide assembly into threaded end of rack housing by hand.
d. Slide rack into housing until ring touches inner guide.
e. Push inner guide into position in housing by tapping on rack end with a plastic hammer as far as it will go.
3.
Apply suitable grease to rack teeth and cover rack teeth with vinyl to protect seals, then install rack. Use caution not to plug air hole of rack
with grease.
4.
Remove vinyl protector from rack, then coat outer box O-rings and seal with suitable lubricant.
5.
Install outer box seal ring, O-rings and oil seal, then the outer box in rack housing.
6.
Protect outer box with cloth, then tighten outer box of rack housing using a pipe wrench. Stake outer box to rack housing using a punch.
7.
Install lower bearing on pinion shaft, if removed, by torquing nut to 29-36 ft.lbs. Stake nut on pinion shaft to secure.
8.
Install pinion shaft with rack positioned so that notch on teeth edge of rack is at center of pinion.
9.
Apply grease to pinion and upper bearing, the install in gear housing.
10.
Install housing cover and torque to 4.3-7.8 inch lbs., then back off 10-20°.
11.
Lock housing cover by torquing locknut to 29-36 ft.lbs.
12.
Install adjustment cover on gear housing and torque to 39-48 inch lbs., then back off cover 45°.
13.
Measure pinion preload. Preload should be .52-1.3 inch lbs. or 21-53 ounces in spring scale is used. If preload is not as specified, readjust
adjustment cover.
14.
Lock housing cover by torquing locknut to 29-36 ft.lbs., then install valve case to gear housing using a suitable tool.
15.
Position rack in suitable vise, then install damper ring, washer and tie rod. Torque tie rod to 43-58 ft.lbs., using tool 49B032303 or equivalent on
all wheel drive models, and stake washer to secure.
16.
Install 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.
18.
Install pressure and return lines to housing.
