Wagon 4WD F4-1781cc 1.8L Turbo (1984)
Fig. 3 Measuring pinion shaft clearance. 1984 manual steering gear
ASSEMBLE
1.
Apply grease to bushings and rack teeth.
2.
Insert rack into pinion side of gearbox.
3.
Locate rack 3.02 inch (76.7 mm) from end of gear housing.
4.
Apply grease to teeth and pinion assembly.
5.
Insert pinion assembly into rack.
6.
Install large size ball bearing snap ring into housing.
7.
Measure clearance parallel to pinion shaft, Figs. 3 and 4. Maximum allowable clearance is .012 inch (.3 mm).
8.
Install oil seal, sleeve, spring, adjusting screw, and O-ring.
9.
Adjust backlash between rack and pinion as follows:
a. Rotate adjusting screw until torque increases greatly, rotate back 15°. This should leave a clearance of .0025 inch (.063 mm) between the
screw tip and sleeve.
b. Torque the locknut to 29-43 ft.lbs. exc. 1984 models, 22-36 ft.lbs. for 1985-88 models.
10.
Rotate pinion by hand to check pinion engagement and backlash.
11.
Install lockwasher on threaded portion of rack end.
12.
Torque ball joint assembly to 58 ft.lbs.
13.
Bend the lockwasher over the ball joint flat.
14.
Apply grease to specified areas and install boots and retaining clips.
Fig. 3 Positioning Tie Rod End. Manual Steering Gear
15.
Install locknut and tie rod end to threaded portion of tie rod, Fig. 5.
